Anisotropic cable sealing gels; and methods for fabricating cable sealing gels

ABSTRACT

Aspects and techniques of the present disclosure relate to a cable sealing structure comprising a cable sealing body including a gel and methods of making anisotropic behavior in cable sealing structures made with a dry silicone gel. In one aspect, various three-dimensional printing techniques are used to make a cable sealing structure that includes a gel. The cable sealing body has a construction that elastically deforms to apply an elastic spring load to the gel. The cable sealing body has a construction with anisotropic deformation characteristics that allows the cable sealing body to be less deformable in one direction than in others. The cable sealing structure can be utilized to seal fiber optic cables more uniformly while limiting the potential of leakage.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of U.S. patent application Ser. No.16/331,424, filed on Mar. 7, 2019, which is a National Stage Applicationof PCT/US2017/050291, filed on Sep. 6, 2017, which claims the benefit ofU.S. Patent Application Ser. No. 62/384,306, filed on Sep. 7, 2016, andclaims the benefit of U.S. Patent Application Ser. No. 62/468,635, filedon Mar. 8, 2017, and claims the benefit of U.S. Patent Application Ser.No. 62/492,713, filed on May 1, 2017, and claims the benefit of U.S.Patent Application Ser. No. 62/384,328, filed on Sep. 7, 2016, andclaims the benefit of U.S. Patent Application Ser. No. 62/468,607, filedon Mar. 8, 2017, and claims the benefit of U.S. Patent Application Ser.No. 62/492,724, filed on May 1, 2017, and claims the benefit of U.S.Patent Application Ser. No. 62/492,740, filed on May 1, 2017, and claimsthe benefit of U.S. Patent Application Ser. No. 62/492,697, filed on May1, 2017, the disclosures of which are incorporated herein by referencein their entireties. To the extent appropriate, a claim of priority ismade to each of the above disclosed applications.

TECHNICAL FIELD

The present disclosure relates generally to cable sealing gels used forsealing telecommunications cables and to methods for producing the cablesealing gels.

BACKGROUND

Telecommunications networks often use enclosures for containing andprotecting telecommunications equipment (e.g., splice locations, opticalsplitters, multi-plexers, connection panels, etc.). Enclosures used inoutside environments are desirably sealed to prevent moisture intrusion.Example gel sealed enclosures are disclosed by U.S. Pat. No. 7,603,018,International Publication Nos. WO-99/41531, and WO-2014/128137 A2.

Pressurized gel-type seals have been used to effectively seal thelocations where telecommunications cables enter and exittelecommunications enclosures. Example pressurized gel-type seals aredisclosed by EP 0442941B1; EP 0587616B1; U.S. Pat. Nos. 5,455,391;6,046,406 and WO 2014/005916.

While gel seals have been effective at sealing cable entry locations,there is a need for constructing gel seals in a way that can addressmultiple structural issues and can meet the structural, mechanical, andgeometrical capabilities necessary for obtaining a proper seal.Improvements are needed in the area of composite gel constructions andmethods of manufacturing such constructions.

FIG. 1 illustrates example pre-shaped gel blocks A and B surrounding acable to create a seal thereabout. As depicted, the gel blocks A and Bform a seal partially circumferentially around the cable while portionsof the cable are not sealed. Such a problem can be described as an “eyeeffect” where a portion of the cable is not properly sealed. The eyeeffect problem can be a potential point of leakage. The points ofpotential leakage can be referred to as triple points because they arelocated where three surfaces meet (e.g., the cable surface and the twogel surfaces).

Gel seals are often pressurized under spring load to encourage the gelto deform or flow into void areas to provide effective sealing.Typically to get a good seal a softer gel is preferred to allow goodflow around the cable to fill potential leakage points (e.g., triplepoints) once pressure is applied. However, a softer gel may be too fluidsuch that the gel may creep out, which can lead to a loss of pressure.This problem is illustrated in FIG. 2 and can be referred to as a “tenteffect”. “Tent effect” can occur when the gel blocks A and B begin tocreep outwardly sideways upon application of pressure due to the gelblocks A and B being softer. The tent effect is generally a result ofthe gel blocks A and B losing containment and stored energy associatedwith a spring load or other source of stored energy.

Thus, although a softer gel may be desirable to create a better sealabout the cable to rid the eye effect, the softer gel may create thetent effect. Improvements in cable sealing structures are desirable thatbalance these competing interests.

SUMMARY

Aspects of the present disclosure relate to structures, designs, andmethods that allow gels to be used to address the eye effect problemwithout having to deal with the tent effect.

Features of the present disclosure relate to sealing structures thatprovide a seal useful for sealing optical fiber cables. The sealingstructures can also provide a seal useful for electrical cables (e.g.,with copper conductors), fiber optic cables, power cables, co-axialcables, twisted pair cables, drop cables, round cables, flat cables,distribution cables, multi-fiber cables, single fiber cables, ribboncables, or other cables. The sealing structures can also be used forsealing enclosures such as telecommunications enclosures. The sealingstructures can be of a gel-type structure including a reinforcingstructure embedded therein. The reinforcing structure can have springlike characteristics to apply a spring load to the gel.

Another aspect of the present disclosure relates to anisotropic sealingstructures that provide a seal useful for sealing optical fiber cables,electrical cables (e.g., with copper conductors), fiber optic cables,power cables, co-axial cables, twisted pair cables, drop cables, roundcables, flat cables, distribution cables, multi-fiber cables, singlefiber cables, ribbon cables, or other cables. The anisotropic sealingstructures can also be used for sealing enclosures such astelecommunications enclosures. The anisotropic sealing structuresprovide anisotropic deformation characteristics. The anisotropic sealingstructures can be of a gel-type structure. Sealing structures withanisotropic deformation characteristics are defined as cable sealingstructures that have a preferred direction of deformation in whichdeformation is greater in one direction than in others. As a result, theanisotropic sealing structures can have different properties indifferent orientations. Seals in accordance with the principles of thepresent disclosure can also be used for sealing applications such as forsealing interfaces between mating pieces of an enclosure.

The sealing structure comprises a cable sealing body including a gel.The cable sealing body can include an x-dimension that extends a long anx-axis, a y-dimension that extends along a y-axis, and a z-dimensionthat extends along a z-axis. The anisotropic deformation characteristicsof the sealing structure allows it to deform less in a cablepass-through direction along the z-axis as compared to at least one ofthe x and y axes in order to help prevent any “eye effect” or “tenteffect” in the seal about the optical fiber cable.

Another aspect of the present disclosure relates to structures, designs,and methods that allow gels to be used to produce anisotropic compositesealing structures for telecommunications enclosures. The method caninclude a step of forming a spacer member that is adapted to define aporous structure of the anisotropic composite seal. The method caninclude the steps of cutting the spacer member into multiple strips andimpregnating the spacer member with a gel or soft sealant material toform a composite sealing structure. The method can also include adeformation of the spacer member, prior to impregnation with a gel orsoft sealant. The method can further include a step of slicing the gelimpregnated spacer to form sealing inserts. Each one of the sealinginserts can have a construction with anisotropic deformationcharacteristics.

A further aspect of the present disclosure relates to a method thatallows gels to be three dimensionally (3D) printed to provide thesealing structures useful for sealing cables (e.g., optical fibercables, electrical cables (e.g., with copper conductors) fiber opticcables, copper cables, power cables, co-axial cables, twisted paircables, drop cables, round cables, flat cables, distribution cables,multi-fiber cables, single fiber cables, ribbon cables, etc.) and forsealing enclosures such as telecommunications enclosures. The sealingstructure can comprise a cable sealing body including a gel and areinforcing material embedded in the gel. The reinforcing material canbe synthetic or natural, in the form of fibers, textiles (knitted, wovenor non-woven), foils and foams in strips or volumes, 3D structures, etc.3D printing the hybrid gel reinforcing material to make the sealingstructure allows for geometric capabilities above standard moldingprocesses. The combination of 3D printing a gel with simultaneousco-dispensing such reinforcing material allows for more complex shapesand/or anisotropic behavior of the gel.

The method can include a 3D printing process including co-dispensing ofthe gel and the reinforcing material in a layer-by-layer manner along aprinting axis by two or more separate printing nozzles. The method caninclude a 3D printing process including co-dispensing of the gel and thereinforcing material in a layer-by-layer manner along a printing axis byone shared printing nozzle. The method can also include a 3D printingprocess including co-dispensing both gel and a textile strip through asingle nozzle in a layer-by-layer manner along a printing axis. It willbe appreciated that 3D printing of the gel and the reinforcing materialmay be achieved in various other ways.

These and other features and advantages will be apparent from a readingof the following detailed description and a review of the associateddrawings. A variety of additional aspects will be set forth in thedescription that follows. These aspects can relate to individualfeatures and to combinations of features. It is to be understood thatboth the foregoing general description and the following detaileddescription are exemplary and explanatory only and are not restrictiveof the broad concepts upon which the embodiments disclosed herein arebased.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of example prior art sealing gel blocksdepicting a potential point of leakage;

FIG. 2 is a schematic diagram of the prior art sealing gel blocks shownin FIG. 1 depicting a loss of energy or containment;

FIG. 3 is a top view of an example enclosure showing a cable sealingstructure positioned therein;

FIG. 4 is a schematic diagram of an example cable sealing structure inaccordance with principles of the present disclosure;

FIG. 4A is a schematic diagram of an example cable sealing structureshowing one gel block sealing about a portion of a telecommunicationscable;

FIG. 5 is a top view of the cable sealing structure shown in FIG. 4;

FIG. 6 is a schematic diagram of a reinforcing structure depicting twodifferent example patterns in accordance with principles of the presentdisclosure;

FIG. 6A is a schematic diagram of one pattern of the reinforcingstructure shown in FIG. 6 embedded in a gel block with atelecommunications cable inserted thereon;

FIG. 6B is a schematic diagram depicting an end view of two gel blockspositioned one on top of the other after the telecommunications cablehas been sealed in accordance with the principles of the presentdisclosure;

FIG. 6C is a schematic diagram of the gel block shown in FIG. 6A showinga reduction in bulging of gel while under pressure of thetelecommunications cable 26 in accordance with the principles of thepresent disclosure;

FIG. 7 is a schematic diagram of two cable sealing structures positionedone on top of the other in accordance with the principles of the presentdisclosure;

FIG. 8 is a schematic diagram depicting an end view of the two cablesealing structures shown in FIG. 7 depicting a complete circumferentialseal about a cable in accordance with the principles of the presentdisclosure;

FIG. 9 is a schematic diagram depicting another example cable sealingstructure in accordance with the principles of the present disclosure;

FIG. 10 is a schematic diagram depicting another example cable sealingstructure in accordance with the principles of the present disclosure;

FIG. 11 is a schematic diagram of the cable sealing structure shown inFIG. 10 with the telecommunications cable positioned thereon;

FIG. 12 is a schematic diagram depicting an end view of two cablesealing structures one on top of the other after the telecommunicationscable has been sealed in accordance with principles of the presentdisclosure;

FIG. 13 is a schematic diagram of the cable sealing structure shown inFIG. 11 showing a reduction in bulging of gel while under pressure ofthe telecommunications cable 26 in accordance with the principles of thepresent disclosure;

FIG. 14 is a schematic diagram depicting yet another example cablesealing structure in accordance with the principles of the presentdisclosure;

FIG. 15 is a schematic diagram of the cable sealing structure shown inFIG. 14 with the telecommunications cable positioned thereon;

FIG. 16 is a schematic diagram depicting an end view of two cablesealing structures one on top of the other after the telecommunicationscable has been sealed in accordance with the principles of the presentdisclosure;

FIG. 17 is a schematic diagram of the cable sealing structure shown inFIG. 15 showing a reduction in bulging of gel while under pressure ofthe telecommunications cable 26 in accordance with the principles of thepresent disclosure;

FIGS. 18-20 are schematic diagrams of example spacer fabrics inaccordance with the principles of the present disclosure;

FIG. 21 is a schematic diagram of an example method of fabricating acable sealing structure that includes an open cell filter foam sheet anda gel material in accordance with the principles of the presentdisclosure;

FIG. 22 is a schematic diagram of an example method of fabricating acable sealing structure that depicts details of cutting the open cellfilter foam sheet of FIG. 21 in accordance with the principles of thepresent disclosure;

FIG. 23 is a schematic diagram of an example method of fabricating acable sealing structure that includes a pre-compressed open cell filterfoam sheet and a gel material in accordance with the principles of thepresent disclosure;

FIG. 24 is a schematic diagram of an example method of fabricating acable sealing structure that includes the pre-compressed open cellfilter foam sheet of FIG. 23 with a substrate provided at one side ofthe pre-compressed open cell filter foam sheet and a gel material inaccordance with the principles of the present disclosure;

FIG. 25 is a schematic diagram of an example three-dimensional printerincluding a dual print head nozzle for fabricating a cable sealingstructure in accordance with principles of the present disclosure;

FIG. 26 is a schematic diagram an example single print head nozzle forfabricating another cable sealing structure;

FIG. 27 is a schematic diagram of the single print head nozzle shown inFIG. 26;

FIG. 27A is a schematic diagram of the single print head nozzle shown inFIG. 27;

FIG. 27B is a schematic cross-sectional diagram of the single print headnozzle shown in FIG. 27;

FIG. 27C is a schematic diagram of the single print head nozzle shown inFIG. 27 dispensing a cable sealing structure in accordance with theprinciples of the present disclosure;

FIG. 27D is a schematic diagram of the single print head nozzle shown inFIG. 27 dispensing a cable sealing structure in accordance with theprinciples of the present disclosure;

FIG. 27E is a schematic diagram of the single print head nozzle shown inFIG. 27 dispensing a seal member inside of an enclosure in accordancewith the principles of the present disclosure; and

FIG. 28 is a schematic diagram of another example single print headnozzle for fabricating a cable sealing structure in accordance with theprinciples of the present disclosure.

DETAILED DESCRIPTION

Reference will now be made in detail to the exemplary aspects of thepresent disclosure that are illustrated in the accompanying drawings.Wherever possible, the same reference numbers will be used throughoutthe drawings to refer to the same or like structure.

The present disclosure generally relates to a cable sealing structuresor other sealing structures. An example cable sealing body includes acable sealing structure 10 (e.g., a composite sealing structure) (seeFIGS. 3 and 4) and a cable sealing body 12 (see FIG. 4). The cablesealing body 12 can include a gel. The cable sealing body 12 can have aconstruction with spring like characteristics such that as the cablesealing body 12 deforms, an elastic load is applied the cable sealingbody 12. As a result, the spring like characteristics cable of the cablesealing structure 10 allows the cable sealing structure 10 toeffectively seal fiber optic cables more uniformly while limiting thepotential of leakage. The cable sealing structure 10 or cable sealingbody 12 can also have a construction with anisotropic deformationcharacteristics that allow the cable sealing body 12 to be lessdeformable in one direction than in others. The cable sealing structure10 can be utilized to seal fiber optic cables more uniformly whilelimiting the potential of leakage (e.g., triple points).

As used herein, the term, “anisotropic,” is defined as having physicalproperties that are different in measurement along different axes ordirections. Therefore, cable sealing structures can have a constructionthat exhibit an anisotropic behavior such that the cable sealingstructures deform more easily or in one direction more than in another.Thus, the cable sealing structure can have a construction in whichdeformation is preferred in one or more orientations as compared to oneor more other orientations.

In one example, cable sealing structures may comprise gel and/or gelcombined with another material such as an elastomer, althoughalternatives are possible. For example, the gel may comprise siliconegel, urea gel, urethane gel, thermoplastic gel, or any suitable gel orgeloid sealing material.

Gels are normally substantially incompressible (e.g., like a liquid)when placed under a compressive force and normally flow and conform totheir surroundings thereby forming sealed contact with other surfaces.Example gels include oil-extended polymers. The polymer may, forexample, comprise an elastomer, or a block copolymer having relativelyhard blocks and relatively elastomeric blocks. Example copolymersinclude styrene-butadiene or styrene-isoprene di-block or tri-blockcopolymers.

In other examples, the polymer of the gel may include one or morestyrene-ethylene-propylene-styrene block copolymers. Example extenderoils used in example gels may, for example, be hydrocarbon oils (e.g.,paraffinic or naphthenic oils or polypropene oils, or mixtures thereof).The cable sealing structures can also include additives such as moisturescavengers, antioxidants, tackifiers, pigments and/or fungicides.

Suitable gels also include those comprising silicone, e.g. apolyorganosiloxane system, polyurethane, polyurea, styrene-butadienecopolymers, styrene-isoprene copolymers,styrene-(ethylene/propylene)-styrene (SEPS) block copolymers (availableunder the tradename Septon™ by Kuraray),styrene-(ethylene-propylene/ethylene-butylene)-styrene block copolymers(available under the tradename Septon™ by Kuraray), and/orstyrene-(ethylene/butylene)-styrene (SEBS) block copolymers (availableunder the tradename Kraton™ by Shell Oil Co.). Suitable extender fluidsinclude mineral oil, vegetable oil, paraffinic oil, silicone oil,plasticizer such as trimellitate, or a mixture of these, generally in anamount of 30 to 90% by volume of the total weight of the gel.

In certain examples, the gel may be a thermosetting gel, e.g. siliconegel, in which the crosslinks are formed through the use ofmultifunctional crosslinking agents, or a thermoplastic gel, in whichmicrophase separation of domains serves as junction points.Thermoplastic elastomers, unlike thermoset elastomers, can be processedusing melt processing techniques.

Thermosetting gels are typically based on silicone chemistry, e.g. apolyorganosiloxane system, and result in a chemically cross linked gel.For example, divinyl polydimethyl siloxane compounds of up to 80,000 cStviscosity may be used with tetra or tri hydride cross linking agents(such as tetrakis dimethyl siloxy silane, SIT 7278 from Gelest forexample), and cross link the divinyl using a platinum catalyst. Thecross link density is kept low by extending the system with non-reactivepolydimethyl siloxane (silicone fluid). Typical formulations contain60-70% silicone fluid, 30-40% divinyl siloxane (80,000 cSt viscosity),1-2% cross linking agent and 5-100 ppm catalyst.

Thermoplastic gels are typically based on mixing some type of extender(usually hydrogenated, refined, paraffin oil—70% paraffin, with a fairlyhigh molecular weight) with block copolymers. The block copolymers areusually based on styrene and a rubber midblock such as Kraton G1651(hydrogenated ethylene butylene midblock) or Septon 2006 (ethylenepropylene midblock). The block copolymers can be styrene-ethylenebutylene-styrene SEBS (tri block) for example or styrene-ethylenebutylene SEB (diblock) for example. Typical diblock copolymers includeKraton G1701H, G1702H, Septon 51001. Typical triblock copolymers includeKraton G1651H, G1652M, G1654H, Septon 58004 and 52006. The hardness maybe adjusted by varying the ratio of diblock to triblock and the amountof extender added. Thermoplastic gel formulations may range from 6%rubber to 20% rubber and 80% diblock (of the total rubber amount) to nodiblock. Optionally other additives may be included in the formulationsincluding UV stabilizers, corrosion inhibitors, fungicide, antioxidants,pigment, etc.

The term “thermoplastic elastomer” refers to an elastomer comprising athermoreversible network. (Definitions of terms relating to thestructure and processing pf sols, gels, networks, and inorganic-organichybrid materials-IUPAC Recommendations 2007-Pure Appl. Chem., Vol. 79,No. 10, pp. 1801-1829, 2007, p. 1811). Thermoplastic elastomers (TPE),sometimes referred to as thermoplastic rubbers, are a class ofcopolymers or a physical mix of polymers (usually a plastic and arubber) which consist of materials with both thermoplastic andelastomeric properties.

The term “thermoplastic” refers to a polymer that softens when exposedto heat and returns to a more rigid condition when cooled. Thesepolymers can typically go through repeated melting and freezing cycles,and can be reshaped upon reheating.

Thermoplastic polymers typically are high-molecular weight polymers,have a chain length capable of forming entanglements, or are longer thana persistence length (i.e., the length in which correlations in thedirection of the tangent are lost). In certain embodiments, thethermoplastic polymer has a molecular weight greater than approximately30,000 g/mol. These polymers may be amorphous or semi-crystalline instructure in their solid state. Examples of thermoplastic polymersinclude, but are not limited to compounds having a backbone containing:polyethylene, polypropylene, acrylonitrile butadiene styrene, acrylic,celluloid, cellulose acetate, cycloolefin copolymer, ethylene vinylacetate, ethylene vinyl alcohol, fluorinated ethylene propylene,fluoroplastics, perfluoroalkoxy copolymer, polyacetal, polyacrylates,polyacryonitrile, polyamine, polyamide-imide, polyaryletherketone,polybutadiene, polybutylene, polybutylene terephthalate,polycaprolactone, polychlorotrifluoroethylene, polyethyleneterephthalate, polycyclohexylene dimethylene terephthalate,polycarbonate, polyhydroxyalkanoates, polyketone, polyester,polyetheretherketone, polyetherketoneketone, polyetherimide,polyethersulfone, polyethylenechlorinates, polyethylenetetrafluoroethylene, polyimide, polylactic acid, polymethylpentene,polyphenylene oxide, polyphenylene sulfide, polyphthalamide,polystyrene, polysulfone, polytrimethylene terephthalate, polyurethane,polyvinyl acetate, polyvinyl chloride, polyvinylidene chloride,styrene-acrylonitrile, and combinations or copolymers thereof. In oneembodiment, the thermoplastic polymer has a polyethylene backbone. Inanother embodiment, the thermoplastic polymer has an acrylic backbone.In still another embodiment, the thermoplastic polymer has a polymethylmethacrylate backbone. In yet another embodiment, the thermoplasticpolymer has a butadiene backbone.

The gel can have measurable properties. For example, in some examples,the gel has a hardness in the range of 24 to 53 Shore 000 Hardness, or80 to 300 g, as measured according to methods known in the art. Incertain examples, the shore hardness gauge is measured according toIS0868, ISO 7619-1, or ASTM D2240. In other examples, hardness can bemeasured on a texture analyzer. For example, a LFRA TextureAnalyzer-Brookfield may include a probe assembly fixed to a motordriven, bi-directional load cell. In such a system, the probe is drivenvertically into the sample at a pre-set speed and to a pre-set depth.The hardness is the amount of force needed to push the probe into thetest sample. In other examples, the gel has a hardness in the range of37 to 45 Shore 000, or 160 to 220 g. In yet other examples, the gel hasa hardness in the range of 38 to Shore 000, or 170 to 200 g. In otherexamples, the gel has a hardness within 10 to 30 on the Shore-000 scale,within 30 to 60 on the Shore-000 scale, or within 10 to 25 on theShore-000 scale.

In some examples, the gel has a durometer of less than 30 on theShore-000 scale. In certain examples, the gel has a durometer in therange of 5 to 50 on the Shore-A scale. The measurement of the durometerdoes not include the reinforcing material, but relates only to the gelmaterial.

In certain examples of the method, the dry silicone gel comprises one ormore of the following properties: (1) a hardness between 100 grams (“g”)and 300 g as measured on a TA-XT2 texture analyzer from TextureTechnologies, (or between 26-53 Shore 000 Hardness), (2) a stressrelaxation between 40% and 60% when the gel is subjected to adeformation of 50% of its original size, (3) a compression set between4% and 20% after 50% strain has applied to the gel for 1000 hours at 70degrees C., and (4) less than 10% oil bleed out after being undercompression of 1.2 atm for 60 days at 60 degrees C. It will beappreciated that there are lots of other test methods that may be usedand properties that may be measurable.

In certain examples, cable sealing structures in accordance with theprinciples of the present disclosure have ultimate elongations greaterthan 100 percent with substantially elastic deformation to an elongationof at least 100 percent.

In other examples, cable sealing structures in accordance with theprinciples of the present disclosure have ultimate elongations of atleast 200 percent, or at least 500 percent, or at least 1000 percent.Ultimate elongation can be determined by the testing protocol set forthat ASTM D412.

As described herein, the techniques of this disclosure may beimplemented in many ways. For example, the techniques of this disclosuremay be implemented in an optical termination enclosure (OTE) 14 as shownin FIG. 3, although alternative enclosures are possible. In one example,aspects of the present disclosure can be used to seal a housing (e.g.,an enclosure, a cabinet, closure, box, pedestal, etc.). In certainexamples, the housing can have a IP40+ sealing performance or better.

Turning to FIG. 3, the enclosure 14 may include a lid member 16 and abase member 18. The enclosure 14 is preferably re-enterable andenvironmentally sealed. The lid member 16 and the base member 18 may beconstructed of a variety of different types of materials includingplastic, metal, and/or other types of materials. Hinges 20 can pivotallyattach the lid member 16 to the base member 18. A set of latches (notshown) may be attached to one of the base member 18 or the lid member 16to secure the parts together or provide latching therebetween, althoughalternatives are possible. For example, mechanical fasteners, such as,screws, bolts, clamps, or other mechanical fastening arrangements can beused.

The base member 18 can define a base sealing receptacle 22 and cableentry ports 24 through which a telecommunications cable 26 (see FIG. 5)passes. The lid member 16 may also define a lid sealing receptacle 28that mates or cooperates with the base sealing receptacle 22 when thelid member 16 and the base member 18 are in a closed position. The cablesealing structure 10 (e.g., composite sealing structure) may be arrangedand configured in the base and lid sealing receptacles 22, 28 of theenclosure 14.

In certain examples, each entry port can be defined in part by the basemember 18 and in part by the lid member 16, and cables can be sealedbetween the composite sealing structure 10 of the base member 18 and thelid member 16. Because the cable sealing structure 10 is relativity softand deformable, the telecommunications cable 26 deforms (e.g.,pressurizes) the cable sealing structure 10 when the cable sealingstructure 10 is pressurized as the enclosure 14 is moved toward theclosed position.

It will be appreciated that the cable sealing structure 10 positionedwithin the base sealing receptacle 22 and the lid sealing receptacle 28may be different or identical. For example, the lid sealing receptacle28 may include a cable sealing structure 10A that is different inmaterial and geometry compared to the cable sealing structure 10Bpositioned in the base sealing receptacle 22, although alternatives arepossible. In other examples, the cable sealing structures 10A and 10Bmay both be identical with respect to their material compositions andgeometries.

Unlike most typical gel-blocks that rely on telecommunicationsenclosures to apply an external spring load thereon to exert a sealingpressure causing the gel to deform about the telecommunications cable26, the cable sealing structure 10 of the present disclosure optionallyhas internal spring load characteristics. The cable sealing structure 10can include a reinforcing structure embedded in the cable sealing body12 to optionally deliver the desired spring load capacity and enhancecontainment as well as sealing about the telecommunications cable 26.Some examples of the reinforcing structures can have inherentelastic/spring-like characteristics that can provide internal springloading within the gel block during sealing. Other reinforcingstructures may not have elastic characteristics and can mainly providereinforcement to the gel block. The reinforcing structure can include avariety of materials, such as, but not limited to, a braided textiles,woven, or non-woven textiles, fibers, yarns, fine metal wires, plastics,glass fibers, foils, foams, mesh, continuous reinforcing elements,discontinuous reinforcing elements, etc. The reinforcing structure canalso be arranged and configured such that the cable sealing structure 10can have any geometry. A suitable shape may be any desired shape, suchas a geometric shape, e.g., a circle, square, rectangle, triangle, orcombinations thereof. In certain examples, the reinforcing structure maybe a preform three-dimensional structure.

As a result, in some examples, it is not necessary that thetelecommunications enclosures apply a spring load to the cable sealingstructure 10 by using an actuator that may typically include a springand a clamp or threaded actuator for compressing the spring topressurize the gel. For example, it will be appreciated that the cablesealing structure 10 may be utilized in telecommunications enclosuresthat do apply an external spring load to the cable sealing structure 10via some type of biasing member.

The cable sealing structure 10 can include gel-blocks that mount withintelecommunications enclosures and rely on the telecommunicationsenclosures to provide relatively rigid containment and pressurization ofthe gel-blocks as the gel-blocks include a spring load for maintainingthe gel in compression.

In other examples, an external biasing member (not shown) may be mountedon the enclosure 14 for pressurizing the gel. According to someexamples, the biasing member may be a spring member. The spring may beformed of any suitable material. For example, the spring can be formedof a metal such as steel, stainless steel or bronze. In some examples,other types of biasing members may be used. For example, the biasingmember may include a coil spring, a Belleville washer, and elastomericspring member, or a deformable/elastic containment structure (e.g., abladder) filled with a compressible fluid.

The biasing member may be used to apply a compressive spring load to thecable sealing structure 10. As a result, the biasing member may exert asealing pressure around the telecommunications cable 26. The pressureapplied to the telecommunications cable 26 can be selectively set sothat an effective seal is provided fully about the telecommunicationscable 26. The telecommunications cable 26 is not overloaded orovercompressed by the pressurized sealant. Such overloading may damagethe telecommunications cable 26, particularly in the case of opticalfibers.

In certain examples, the cable sealing structure 10 optionally does nothave pre-formed notches or openings for receiving the telecommunicationscable 26. In other examples, pre-formed notches, depressions, oropenings can be provided in the gel.

Turning now to FIGS. 4 and 5, the example cable sealing structure 10 caninclude a first gel block 30 (e.g., gel insert) and a second gel block32 (e.g., gel insert). In the depicted example, the first and second gelblocks 30, 32 are positioned one on top of the other such that the firstand second gel blocks 30, 32 can be used as a pair, althoughalternatives are possible. FIG. 4A shows one gel block. The gel blockwould typically cooperate with another gel block as shown in FIG. 4 toprovide full sealing about a cable. In certain examples, the gel blockcan be applied in enclosures that may have axial and/or transversalcompression designs. As such, in certain examples, axially andtransversally compressible design assemblies may include reinforced gelblocks positioned between two support structures or in a clampshell. Thegel blocks can meet at a sealing interface 27 or sealed seam. It will beappreciated that the first and second gel blocks 30, 32 may haveidentical material compositions and geometries, although alternativesare possible. For example, the first and second gel blocks 30, 32 mayeach have different material compositions and the first and second gelblocks 30, 32 may each have different geometries. It will be appreciatedthat the first and second gel blocks 30, 32 may be used with other cablesealing structures 10.

Although rectangular gel blocks are depicted, it will be appreciatedthat the cable sealing structure 10 may be arranged and configured as astrip, or other type of arrangement such as a cylindrical block, atruncated triangular block, a wedge-shaped block, a portion of acylinder, a portion of an annulus, or other shapes. The first and secondgel blocks 30, 32 can be arranged and configured to mate or cooperatetogether in an enclosure to form a seal about a telecommunicationscable. The first and second gel blocks 30, 32 each include a cablesealing body 34, 36 including a gel. In the illustrated example, thefirst gel block 30 is identical to the second gel block 32; as such,only the first gel block 30 will be described herein. Those of skill inthis art will appreciate that the discussion of the first gel block 30applies equally to the second gel block 32. Also, in some examples thefirst and second gel blocks 30, 32 may not be identical.

The cable sealing body 34 of the first gel block 30 can include anx-dimension X that extends along an x-axis, a y-dimension Y that extendsalong a y-axis, and a z-dimension Z that extends along a z-axis. In oneexample, the x-axis defines a length axis of the cable sealing body, they-axis defines a height axis of the cable sealing body, and the z-axisdefines a depth axis of the cable sealing body. In this example, thez-axis corresponds to a cable pass-through direction D.

The anisotropic behavior of the cable sealing body 34 of the cablesealing structure 10 allows the cable sealing body 34 to move less alongthe z-axis or the cable pass-through direction D as compared to at leastone of the x and y axes. Thus, deformation is preferred along the x andy axes as compared to the z-axis. For example, the cable sealing body 34can be more flexible and/or flowable along the x and y axes while beingmore stiff and/or non-flowable, restricted along the z-axis. Because thecable sealing body 34 can have anisotropic deformation characteristicswhich resist deformation along the z-axis, a softer gel can be usedwithout experiencing tenting during pressurization of the sealingstructure. A softer gel can readily flow in the x and y dimensions whenload pressure is applied to the cable sealing body 34. The pressureforces the gel to deform and move effectively around thetelecommunications cable 26 through deformation in the x and yorientations due to the softness of the gel while the reinforcement(e.g., reinforcing structure) limits movement in the cable pass-throughdirection D to reduce tenting and to provide effective gel containment.As a result, the stretching and/or telescoping effect of the cablesealing body 34 of the cable sealing structure 10 can be reduced tothereby help limit the eye and tent effects (see FIG. 4). Because thecable sealing body 34 can be more contained more effectively within atelecommunications cable enclosure, it is not necessary that thetelecommunications cable enclosure match closely with a cable diameter.As such, the telecommunications cable enclosure can be arranged andconfigured to receive increased cable diameter ranges without having aneed for closure entry adaptions or cable size matching inserts.

In some examples, pre-formed notches, openings, or passages can beformed in the composite sealing structure 10 for receiving cables. Inother examples, no pre-formed notches or openings are provided such thatspace for the cables through the gel block is provided entirely bydeformation of the sealing structures. In some examples, relativelysmall pre-formed passages can accommodate a wide range of cable sizes.Pre-formed cable passages may or may not be provided at the sealinginterface between two composite cable sealing structures 10.

In one example, the cable sealing body 34 of the cable sealing structure10 can include at least one reinforcing structure 38. In the examplesdepicted in FIGS. 4 and 5, the cable sealing body 34 includes aplurality of separately discrete reinforcing structures 38. Theplurality of separately discrete reinforcing structures 38 are generallyaligned along the z-axis of the cable sealing body 34, althoughalternatives are possible. In certain examples, the plurality ofseparately discrete reinforcing structures 38 may not be exclusivelyaligned along the z-axis. The plurality of separately discretereinforcing structures 38 are generally aligned along the axis ofreduced deformation which provides the anisotropic behavior. Thereinforcing structures 38 help to restrict the movement of the cablesealing body 34 along the z-axis that corresponds to the cablepass-through direction D. As a result, the cable sealing body 34 is lessdeformable along the z-axis as compared to both the x and y axes toachieve anisotropic behavior. Such a configuration helps to limit theeye and tent effect that can typically result form using a softer gel.

In certain examples, the cable sealing body 34 is less deformable alongthe z-axis as compared to at least one of the x and y axes. Thus,deformation is preferred along the x and y axes as compared to thez-axis. That is, the cable sealing body 34 can be more flexible and/orflowable along the x and y axes while being more stiff and/ornon-flowable, restricted along the z-axis. Because the able sealing body34 can have anisotropic deformation characteristics which resistdeformation along the z-axis, a softer gel can be used withoutexperiencing tenting during pressurization of the cable sealingstructure 10. A softer gel can readily flow into x and y dimensions whenload pressure is applied to the cable sealing body 34. The pressureforces the gel to move effectively around the telecommunications cable26 through deformation into x and y orientations while the reinforcement(e.g., reinforcing structure) limits movement in the cable pass-throughdirection D to reduce tenting and to provide effective gel containment.

The reinforcing structure 38 can have spring like characteristics withflexibility along the y-axis such that the reinforcing structure 38 isconfigured to take an radial load of the telecommunications cable 26being applied. The reinforcing structure 38 can compress or buckle underthe load of the telecommunications cable 26 being applied. As a result,the spring effect of the reinforcing structure 38 can cause the gel ofthe cable sealing body 34 to be pushed upwardly to wrap thetelecommunications cable 26 circumference better and help to limit theeye and tent effect. For example, the cable sealing body 34 can applyopposing biasing force or a spring effect along the z-axis whileallowing movement along the y-axis, which helps to close the eye-effect.As a result, a complete seal can be formed about the telecommunicationscable 26 as indicated by arrow 11 (see FIG. 4) while restrictingmovement in other areas or orientations. Spring biasing can be providedin the x-dimension and/or the y-dimension and/or the z-dimension tospring bias the gel in a manner that helps prevent an “eye” effect atthe seal around the telecommunications cable 26 to provide effectivetriple point sealing. Thus, the reinforcing structure 38 can beconfigured to intentionally spring bias the gel into the triple pointregions during sealing under pressure.

In certain examples, the reinforcing structure 38 can cause the gel ofthe cable sealing body 34 to migrate in various directions about thetelecommunications cable 26 to create a complete seal while restrictingmovement in other areas or orientations.

In certain examples, the reinforcing structure 38 can have a reboundeffect such that the reinforcing structure 38 is arranged and configuredto return back to its pre-deformed shape. The reinforcing structure 38can be embedded into the cable sealing body 34 to limit stretching alongthe z-axis by having a desired stiffness or flexibility in the Zdimension, to allow stretching along the z-axis, and to be compressiblealong the y-axis but having a spring/rebound effect. The reinforcingstructure 38 can compress under axial load of the cable 26 to provide aspring effect pushing the gel upwards such that gel of the cable sealingbody 34 can better seal around the cable 26 and limit the eye effect.The reinforcing structure 38 can rebound to its pre-deformed shape toprovide an up and down spring elastic load to the gel of the cablesealing body 34.

In some examples, the cable sealing body 34 of the cable sealingstructure 10 is less deformable along the z-axis as compared to at leastone of the x and y axes. In other examples, the at least one reinforcingstructure 38 can be oriented and positioned in the cable sealing body 34of the cable sealing structure 10 such that the cable sealing body 34 ismore deformable along the x-axis as compared to at least one of the yand z axes. In certain examples, the at least one reinforcing structure38 can be oriented and positioned in the gel of the cable sealing body34 such that the cable sealing body 34 is more deformable along thex-axis as compared to both the y and z axes.

In certain examples, the reinforcing structure 38 may include a springmesh, screen, or netting, braided textiles, woven, or non-woventextiles, fibers, yarns, fine metal wires, plastics, glass fibers,foils, foams, etc., although alternatives are possible. In someexamples, the reinforcing structure 38 may include a metal, extensiblefabric, a 3D textile or spacer fabric, an anisotropic 3D textile orknitted fabric, a biasing member, such as a spring, strength members,elastics, a preform three-dimensional structure, although alternativesare possible. The reinforcing structure 38 can include a continuousbead, thread, or other shape of uninterrupted, interconnected materialor can be formed by a plurality of separate non-continuous pieces.

In other examples, both of the cable sealing bodies 34, 36 can have aconstruction with anisotropic deformation characteristics. Theanisotropic behavior of the cable sealing body 34 of the cable sealingstructure 10 allows the cable sealing body 34 to move less along thez-axis or the cable pass-through direction D as compared to at least oneof the x and y axes. For example, the cable sealing body 34 can be moreflexible and/or flowable along the x and y axes while being stiff and/ornon-flowable, restricted along the z-axis.

The cable sealing body 34 can have anisotropic deformationcharacteristics that include a softer gel which can readily flow into xand y dimensions, when load pressure is applied to the cable sealingbody 34 the pressure forces the gel to deform and move effectivelyaround the telecommunications cable 26 through deformation in the x andy orientations due to the softness of the gel while the reinforcement(e.g., reinforcing structure) limits movement in the cable pass-throughdirection D to reduce tenting and to provide effective gel containment.As a result, the stretching and/or telescoping effect of the cablesealing body 34 of the cable sealing structure 10 can be reduced tothereby limit the eye and tent effects. The cable sealing body 34 canalso be more contained more effectively within a telecommunicationscable enclosure such that it is not necessary that thetelecommunications cable enclosure match closely with a cable diameter.As such, the telecommunications cable enclosure can be arranged andconfigured to receive increased cable dieter ranges without having aneed for closure entry adaptions or cable size matching inserts. In someexamples, pre-formed notches or passages can be formed in the cablesealing structure 10 for receiving cables. In other examples, nopre-formed notches or openings are provided such that space for thecables through the gel block is provided entirely by deformation of thecable sealing structures 10. In some examples, relatively smallpre-formed passages can accommodate a wide range of cable sizes.Pre-formed cable passages may or may not be provided at the sealinginterface between two composite sealing structures.

Thus, an advantage of the cable sealing structure 10 is that a widervariety of cable sizes and shapes can be sealed with a single sealingstructure and closure geometry. The cable sealing structure 10 canprovide for fewer variants in cable entry designs at the cable entryportion of an enclosure, which can make for a much simpler and moreversatile seal that can be more cost effective and design insensitive.Also, less force can be required to make the gel accommodate to thecable, which can make installation easier and require less structurestrength for the enclosure.

Turning now to FIG. 6, another example reinforcing structure 38A isdepicted. The reinforcing structure 38A can be arranged and configuredto be embedded into the cable sealing body 12.

The reinforcing structure 38A includes spring like characteristics thatprovide a spring and rebound effect. The rebound effect adds additionalfeatures and advantages to the anisotropic behavior of the cable sealingstructure 10. The reinforcing structure 38A can include a base member 40having a first end and an opposite second end; a plurality of deformableprojecting rib members 42 extending from the base at the first end;and/or a plurality of non-deformable projecting rib members 44 extendingfrom the base at the second end. As depicted, the plurality ofdeformable projecting rib members 42 are positioned in a first portion46 of the reinforcing structure 38A and the plurality of non-deformableprojecting rib members 44 are positioned in a second portion 48 of thereinforcing structure 38A, although alternatives are possible. Incertain examples, the plurality of deformable projecting rib members 42and the plurality of non-deformable projecting rib members 44 may beintertwined or alternately positioned relative to one another. Theplurality of deformable projecting rib members 42 and the plurality ofnon-deformable projecting rib members 44 may be combined together in asingle reinforcing structure.

In other examples, the plurality of deformable projecting rib members 42and the plurality of non-deformable projecting rib members 44 may beconfigured as separate reinforcing structures respectively positioned intheir respective cable sealing bodies 12. In still other examples, theplurality of deformable projecting rib members 42 and the plurality ofnon-deformable projecting rib members 44 may be respectively combinedwith a different reinforcing structure. The example reinforcingstructure 38A can provide a structure that is deformable along they-axis and is non-deformable or have limited deformability along thez-axis.

The configuration of the reinforcing structure 38A provides the cablesealing body 12 with optimal sealing performance. The reinforcingstructure 38A can have reduced stiffness along the y-axis to provide thedesired spring and rebound effect in the first portion 46 as compared tothe second portion 48 where the stiffness may not be as low. It will beappreciated that other variations of reinforcing structures, shapesand/or patterns are possible.

The plurality of deformable projecting rib members 42 are arranged andconfigured to provide spring like characteristics, although alternativesare possible. In one example, the plurality of deformable projecting ribmembers 42 can each have two segments, an elastic segment 50 and aninelastic segment 52. The elastic segment 50 can be configured withspring like, elastic characteristics. For example, the elastic segment50 can be arranged and configured to apply a biasing force or springeffect while under a radial load of the telecommunications cable 26.This spring effect will cause the gel of the cable sealing body 12 tomove upward to create a better seal around the cable circumference.Thereafter, the elastic segment 50 can rebound to its pre-deformedshape. This biasing force or spring effect provides an “up and down”spring elastic load to the gel. The inelastic segment 52 can be anon-flexible or stiff structure.

FIG. 6A shows the reinforcing structure 38A including the plurality ofnon-deformable projecting rib members 44 embedded in a gel block. Theplurality of non-deformable projecting rib members 44 can be arrangedand configured to limit flexibility, although alternatives are possible.The plurality of non-deformable projecting rib members 44 are arrangedand configured adjacent to the telecommunications cable 26. Theplurality of non-deformable projecting rib members 44 that are shownpositioned generally under the telecommunications cable 26 can bearranged and configured to collapse under pressure.

The plurality of non-deformable projecting rib members 44 can includepanels 54 that are generally inelastic compared with the plurality ofdeformable projecting rib members 42. The panels 54 of the reinforcingstructure 38A can be configured to allow the cable sealing body 12 tomove less along the z-axis or the cable pass-through direction D ascompared to at least one of the x and y axes. For example, the cablesealing body 12 can be more flexible and/or flowable along the x and yaxes while being more stiff and/or non-flowable, restricted along thez-axis.

FIG. 6B shows two gel blocks, one on top of the other, each oneincluding the plurality of non-deformable projecting rib members 44embedded therein. Although gel blocks are depicted, it will beappreciated that any other type of arrangement may be used. In thisexample, the plurality of non-deformable projecting rib members 44 isgenerally surrounding the telecommunications cable 26 to form a completeseal. While the plurality of non-deformable projecting rib members 44positioned generally under the telecommunications cable 26 collapseunder pressure, the surrounding non-deformable projecting rib members 44can be arranged and configured to rebound and force the gel into cornersor areas (e.g., triple points) surrounding the telecommunications cable26. It will be appreciated that other portions of the reinforcingstructure 38A surrounding the telecommunications cable 26 can bestrategically positioned or oriented to control movement of the gelwithin the cable sealing body 12 to allow the gel to fill in spaces(e.g., voids, openings, etc.) around the telecommunications cable 26.

In the depicted example, the non-deformable projecting rib members 44embedded in a top gel block 45 (e.g., first gel block) can be generallyrigid such that under pressure, the non-deformable projecting ribmembers 44 can press the gel in a downwards direction such that the gelmoves about the telecommunications cable 26. The non-deformableprojecting rib members 44 embedded in a bottom gel block 47 (e.g.,second gel block) can be generally rigid such that while under pressure,the non-deformable projecting rib members 44 can press the gel in anupwards direction around the telecommunications cable 26. As such, thegel fills those areas around the telecommunications cable 26 which canhelp to reduce the “eye effect”.

FIG. 6C shows a reduction in bulging of the gel while under pressure ofthe telecommunications cable 26. The plurality of non-deformableprojecting rib members 44 can help to keep the gel in place such thatless bulging of the gel occurs under pressure. As such, the “tenteffect” can be reduced.

Turning to FIG. 7, another example cable sealing structure 10B includinggel blocks 56, 58 is shown. In the depicted example, the gel blocks 56,58 are positioned one on top of the other such that the two gel blocks56, 58 can be used as a pair. It will be appreciated that the gel blocks56, 58 may be identical in material composition and geometry, althoughalternatives are possible. For example, the two gel blocks 56, 58 mayeach have different compositions and may each have different geometries.It will be appreciated that the gel blocks 56, 58 may be used with othercable sealing structures 10.

Although rectangular gel blocks are depicted, it will be appreciatedthat the cable sealing structure 10B may be arranged and configured as astrip, or other type of arrangement such as a cylindrical block, atruncated triangular block, a wedge-shaped block, a portion of acylinder, a portion of an annulus, or other shapes. The gel blocks 56,58 can be arranged and configured to mate or cooperate together in anenclosure to form a seal about the telecommunications cable 26. The gelblocks 56, 58 each include a cable sealing body 60, 62 including a gel.Both of the cable sealing bodies 60, 62 has a construction with springlike characteristics and/or anisotropic deformation characteristics. Inthe illustrated example, the gel block 56 is identical to the gel block58; as such, only the gel block 56 will be described herein. Those ofskill in this art will appreciate that the discussion of the gel block56 applies equally to the other gel block 58. Also, in some examples thegel blocks 56, 58 may not be identical.

The cable sealing body 60 of the gel block 56 can include an x-dimensionX that extends along an x-axis, a y-dimension Y that extends along ay-axis and a z-dimension Z that extends along a z-axis. In this example,the z-axis corresponds to a cable pass-through direction D₁. The springlike characterization or anisotropic behavior of the cable sealingstructure 10B can be configured to allow the cable sealing body 60 todeform less easily along the z-axis or the cable pass-through directionD₁ as compared to at least one of the x and y axes. For example, thecable sealing body 60 can be more flexible and/or flowable along the xand y axes while being more stiff and/or non-flowable, restricted alongthe z-axis. The example cable sealing body 60 of the cable sealingstructure 10B can include a reinforcing structure 38B. The reinforcingstructure 38B can have elastic characteristics. The reinforcingstructure 38B depicted includes an extensible fabric or elastic textile,although alternatives are possible. The textile may be any appropriateknitted, woven or non-woven material, preferably the fabric is woven.The reinforcing structure 38B can include an extensible article thatbecomes increasingly separated as the article is stretched along thex-axis and/or as the cable sealing body 60 of the cable sealingstructure 10B is extended or deformed along the x-axis. In certainexamples, one or more articles may be embedded in the cable sealing body60. Suitably the extensible or elastic textile can comprise elasticfibers. The term fiber when used herein includes threads, filaments andyarns.

In one example, the reinforcing structure 38B can be folded or shapedsuch that a plurality of ribs 64 are formed that adopt a linearconfiguration generally aligned along the z-axis of the cable sealingbody 60 of the cable sealing structure 10B. The configuration can helpto restrict movement or deformation along the z-axis that corresponds tothe cable pass-through direction D₁. As a result, the cable sealing body60 is less deformable along the z-axis as compared to both the x and yaxes. Similar to the cable sealing body 34 of the cable sealingstructure 10 described, the stretching and/or telescoping effect of thecable sealing body 60 of the cable sealing structure 10B can be reducedto thereby limit the eye and tent effects. (see FIG. 8).

The spring like behavior of the reinforcing structure 38B can compressunder radial load caused by the telecommunications cable 26 beingpressed into the sealing structure 10 and can be configured to push thegel within the cable sealing body 60 upwards towards the triple pointsand around the circumference of the telecommunications cable 26. Thisspring characteristic allows movement along the y-axis while applyingopposing biasing spring force toward the non-deflected shape (e.g.,along the z-axis) to better close the eye effect and create an improvedseal. In certain examples, the reinforcing structure 38B may have arebound effect in the gel of the cable sealing body 60 such that itreturns to its pre-deformed shape. The reinforcing structure 3B8 canrebound to its pre-deformed shape to provide an up and down springelastic load to the gel of the cable sealing body 34.

In one example, the reinforcing structure 38B can be arranged andconfigured in a desired arrangement (e.g. in a zig-zag), althoughalternatives are possible. The zig zag configuration can be arrangedfrom top to bottom in the cable sealing body 60 of the cable sealingstructure 10B. As a result, the plurality of ribs 64 can be formed onthe top and bottom of the cable sealing body 60. It will be appreciatedthat the shape or configuration of the reinforcing structure 38B mayvary with other examples.

In certain examples, the reinforcing structure 38B can have a width nogreater than a width of the cable sealing body 60 of the cable sealingstructure 10B. In certain examples, the cable sealing body 60 may beslightly longer in width than the reinforcing structure 38B to helpreduce any wicking. The reinforcing structure 38B can stretch (e.g.,flex in and out) lengthwise along the x-axis while maintaining aconstant width. The reinforcing structure 38B can have a softness thatallows it to conform and deform in a desired direction.

Turning to FIG. 9, another example cable sealing structure 10C includinga gel block 66 is shown. Although rectangular gel blocks are depicted,it will be appreciated that the cable sealing structure 10C may bearranged and configured as a strip, or other type of arrangement such asa cylindrical block, a truncated triangular block, a wedge-shaped block,a portion of a cylinder, a portion of an annulus, or other shapes. Thegel block 66 includes features of the gel blocks 30, 32, 56, 58previously described with reference to FIGS. 4 and 7. The gel block 66can include a cable sealing body 68 including a gel. The cable sealingbody 68 can have a spring like or elastic construction and/or aconstruction with anisotropic deformation characteristics.

The cable sealing body 68 of the gel block 66 can include an x-dimensionX that extends along an x-axis, a y-dimension Y that extends along ay-axis, and a z-dimension Z that extends along a z-axis. In thisexample, the z-axis corresponds to a cable pass-through direction D₂.The spring like behavior of the cable sealing structure 10C can beconfigured to allow the cable sealing body 68 to deform less easilyalong the z-axis or the cable pass-through direction D₂ as compared toat least one of the x and y axes. For example, the cable sealing body 68can be more flexible and/or flowable along the x and y axes while beingmore stiff and/or non-flowable, restricted along the z-axis. The examplecable sealing body 68 of the cable sealing structure 10C can include areinforcing structure 38C. The example reinforcing structure 38Cdepicted includes a three dimensional structure. The reinforcingstructure 38C can be, for example, a textile, although alternatives arepossible. The textile may be any appropriate knitted, woven or non-wovenmaterial. Suitably the fabric can comprise elastic fibers. The termfiber when used herein includes threads, filaments and yarns. In otherexamples, the reinforcing structure 38C may include a spring mesh,screen, or netting, a metal, strength members, elastics, a preformthree-dimensional structure, although alternatives are possible.

The reinforcing structure 38C can have a pre-defined shape that can beheld together within the cable sealing structure 10C. As a result, thereinforcing structure 38C has a self-supporting shape, althoughalternatives are possible. In certain examples, the reinforcingstructure 38C may have a rebound effect in the gel of the cable sealingbody 68 such that it returns to its pre-defined shape.

The example reinforcing structure 38C is configured as a threedimensional (3-D) block matrix including a plurality of loops or apattern of circles, although alternatives are possible. It will beappreciated that a variety of matrix materials and patterns arepossible. The reinforcing structure 38C can have a construction withelastic characteristics, which allows movement along the y-directionwhile applying an opposing biasing spring force along the z-axis to helplimit the eye effect. The 3-D configuration of the reinforcing structure38C provides for a uniform spring within the cable sealing body 68. Thereinforcing structure 38C can compress under radial load caused by thetelecommunications cable 26 being pressed into the sealing structure 10Cand can be configured to push the gel of the cable sealing body 68upwards toward the triple points to provide a better seal around thecable 26. The reinforcing structure 38C can also rebound to itspre-deformed shape providing an up and down spring elastic load to thegel. In certain examples, the reinforcing structure 38C can also haveanisotropic deformation characteristics that allow extension in onedirection while limiting or restricting deformation in other directions.

The cable sealing body 68 (e.g., reinforcements) can include lengthwisestrut members 70 that provide longitudinal support. The strut members 70can help to prevent the cable sealing body 68 from stretching in adirection parallel with the strut members 70 along the z-axis, therebylimiting any depth movement. For example, the depicted configuration canhelp to restrict movement or deformation along the z-axis thatcorresponds to a cable pass-through direction or the direction of thelengthwise strut members 70. As a result, the cable sealing body 68 isless deformable along the z-axis as compared to both the x and y axes.The cable sealing body 68 can stretch in a direction along the y-axisand vary the height as the circled matrix can squeeze together. Thecable sealing body 68 can stretch in a direction along the x-axisbecause the circled matrix can be extended thereby varying the length.Similar to the cable sealing body 34 of the cable sealing structure 10described, the stretching and/or telescoping effect of the cable sealingbody 68 of the cable sealing structure 10C can be reduced to therebylimit the eye and tent effects.

The reinforcing structure 38C can form a bond with the gel of the cablesealing body 68 to help limit movement of the gel in a specificdirection. In one example, the gel can be molded over the reinforcingstructure 38C, although alternatives are possible. For example, the gelcan be injection molded and cured over the reinforcing structure 38C. Inother examples, the gel can be extruded around any of the reinforcingstructures described herein. Details of the fabrication of the cablessealing structures will be described later.

Turning to FIG. 10, another example cable sealing structure 10Dincluding a gel block 72 is shown. Although gel a block is depicted, itwill be appreciated that the cable sealing structure 10D may be arrangedand configured as a strip, or other type of arrangement such as acylindrical block, a truncated triangular block, a wedge-shaped block, aportion of a cylinder, a portion of an annulus, or other shapes. The gelblock 72 includes features of the other gel blocks 30, 32, 56, 58previously described with reference to FIGS. 4 and 7. The gel block 72can include a cable sealing body 74 including a gel.

The cable sealing body 74 of the gel block 72 can include an x-dimensionX that extends along an x-axis, a y-dimension Y that extends along ay-axis, and a z-dimension Z that extends along a z-axis. In thisexample, the z-axis corresponds to a cable pass-through direction D₃.The spring like behavior of the cable sealing structure 10C can beconfigured to allow the cable sealing body 74 to deform less easilyalong the z-axis or the cable pass-through direction D₃ as compared toat least one of the x and y axes. For example, the cable sealing body 74can be more flexible and/or flowable along the x and y axes while beingmore stiff and/or non-flowable, restricted along the z-axis. The examplecable sealing body 74 of the cable sealing structure 10D can include areinforcing structure 38D. In certain examples, the reinforcingstructure 38D can include a spacer fabric that can include rigidstructures (e.g., knitted yarns, fibers, strands, knitted structures,rigid non-deformable projecting rib members, etc.). The reinforcingstructure 38D may include or be composed of knitted fabrics, a springmesh, screen, or netting, fibers, yarns, metal, strength members,elastics, a preform three-dimensional structure, although alternativesare possible.

In certain examples, the reinforcing structure 38D may have a reboundeffect in the gel of the cable sealing body 74 such that it returns toits pre-deformed shape. The reinforcing structure 38D can have apre-defined shape that is impregnated with a gel to form the cablesealing structure 10D and can be held together within the cable sealingstructure 10D. As a result, the reinforcing structure 38D can have aself-supporting shape, although alternatives are possible.

The example reinforcing structure 38D is configured as a threedimensional (3-D) block matrix including a plurality of knittedstructures that may be made of strands that provide tensile strengthalong their length and are generally rigid or non-stretchable intension, although alternatives are possible. It will be appreciated thata variety of matrix materials and patterns are possible. The pluralityof knitted structures can be arranged and configured to deform underpressure or in response to a lateral load while still providing enoughstiffness to control movement of the gel within the cable sealing body74 to specific areas therein in order to form a complete cable sealwhile restricting movement in other areas or orientations. Thereinforcing structure 38D can have a construction with elasticcharacteristics, which allows movement along the y-direction whileapplying an opposing biasing spring force along the z-axis to help limitthe “eye effect.” Spring biasing can be provided in the x-dimensionand/or the y-dimension and/or the z-dimension to spring bias the gel ina manner that helps prevent an “eye effect” at the seal around the cableto provide effective triple point sealing. Thus, the reinforcingstructure 38C can be configured to intentionally spring bias the gelinto the triple point regions during sealing under pressure.

Turning to FIG. 11, the reinforcing structure 38D can compress underradial load caused by the telecommunications cable 26 being pressed intothe cable sealing structure 10D and can be configured to push gel withinthe cable sealing body 74 upwards toward the triple point to provide abetter seal around the telecommunications cable 26. The 3-Dconfiguration of the reinforcing structure 38D provides for a uniformspring within the cable sealing body 74.

Turning to FIG. 12, the cable sealing structure 10D is positioned on topof another cable sealing structure 10E (e.g., sealed position) to createa complete seal about the telecommunications cable 26. The cable sealingstructures 10D and 10E can be identical or different in composition andgeometry. In the example shown, the cable sealing structures 10D, 10Eeach have the same reinforcing structure 38D and gel composition,although alternatives are possible. While under pressure caused bypressurizing the cable sealing structures 10D, 10E about thetelecommunications cable 26, portions of the reinforcing structure 38Dpositioned generally under the telecommunications cable 26 can collapse.It will be appreciated that other portions of the reinforcing structure38D surrounding the telecommunications cable 26 can be strategicallypositioned or oriented to move the gel within the cable sealing body 74to allow the gel to fill in spaces (e.g., voids, openings, etc.) aroundthe telecommunications cable 26. For example, while in the sealedposition and while being pressurized about the telecommunications cable26, the reinforcing structure 38D can be strategically positioned ororiented to move the gel within the cable sealing body 74 or force thegel into corners or areas (e.g., triple points) surrounding thetelecommunications cable 26 to help reduce the “eye effect”. As such, arebound effect for combating the “eye effect” can be provided. The gelmaterial fills those areas about the telecommunications cable 26 toprovide for a complete seal without leakage.

The reinforcing structure 38D can also rebound to its pre-deformed shapeproviding an up and down spring elastic load to the gel. In certainexamples, the reinforcing structure 38D can also have anisotropicdeformation characteristics that allow extension in one direction whilelimiting or restricting deformation in other directions.

FIG. 13 shows a reduction in bulging of the gel while under pressure ofthe telecommunications cable 26. The fibers or non-deformable projectingrib members of the reinforcing structure 38D can help to keep the gel inplace such that less bulging of the gel occurs under pressure. As such,the “tent effect” can be reduced.

Turning to FIG.14, another example cable sealing structure 10F includinga gel block 76 is shown. Although a rectangular gel block is depicted,it will be appreciated that the cable sealing structure 10F may bearranged and configured as a strip, or other type of arrangement such asa cylindrical block, a truncated triangular block, a wedge-shaped block,a portion of a cylinder, a portion of an annulus, or other shapes. Thegel block 76 includes features of the other gel blocks 30, 32, 56, 58,72 previously described with reference to FIGS. 4, 7, and 10. The gelblock 76 can include a cable sealing body 78 including a gel.

The cable sealing body 78 of the gel block 76 can include an x-dimensionX that extends along an x-axis, a y-dimension Y that extends along ay-axis, and a z-dimension Z that extends along a z-axis. In thisexample, the z-axis corresponds to a cable pass-through direction D₄.The spring like behavior of the cable sealing structure 10F can beconfigured to allow the cable sealing body 78 to deform less easilyalong the z-axis or the cable pass-through direction D₄ as compared toat least one of the x and y axes. For example, the cable sealing body 78can be more flexible and/or flowable along the x and y axes while beingmore stiff and/or non-flowable, restricted along the z-axis. The examplecable sealing body 78 of the cable sealing structure 10F can include areinforcing structure 38E. In one example, the reinforcing structure 38Ecan include a spacer fabric that can include rigid structures with acombination of knitted structures, yarns/fibers (e.g., knitted rigidyarns, knitted fabrics, filaments, threads, rigid non-deformableprojecting rib members, etc.) that can be generally rigid ornon-stretchable in tension but deformable in compression in response toa lateral load. In other examples, the reinforcing structure 38E mayinclude or be composed of a spring mesh, screen, or netting, a metal,strength members, elastics, a preform three-dimensional structure,although alternatives are possible.

In certain examples, the reinforcing structure 38E may have a reboundeffect in the gel of the cable sealing body 78 such that it returns toits pre-deformed shape. The reinforcing structure 38E can have apre-defined shape that is impregnated with a gel material to form thecable sealing structure 10F. That is, the reinforcing structure 38E canhave a pre-defined shape that can be held together within the cablesealing structure 10F. As a result, the reinforcing structure 38E canhave a self-supporting shape, although alternatives are possible.

The example reinforcing structure 38E is configured as a (threedimensional block (3-D) matrix including a plurality of knittedstructures, although alternatives are possible. It will be appreciatedthat a variety of matrix materials and patterns are possible. Theplurality of knitted structures can be arranged and configured to deformunder pressure or in response to a lateral load while still providingenough stiffness to move the gel within the cable sealing body 78 tospecific areas therein in order to form a complete cable seal. Thereinforcing structure 38E can have a construction with elasticcharacteristics, which allows movement along the y-direction whileapplying an opposing biasing spring force along the z-axis to help limitthe “eye effect.” The 3-D configuration of the reinforcing structure 38Ecan provide for a uniform spring within the cable sealing body 78.

Turning to FIG. 15, the reinforcing structure 38E can compress underradial load caused by the telecommunications cable 26 being pressed intothe cable sealing structures 10F, 10G (e.g., the cable sealingstructures 10F, 10G are pressurized about the telecommunications cable26) and can be configured to push gel within the cable sealing body 78upwards towards the triple point to provide a better seal around thetelecommunications cable 26.

Turning to FIG. 16, the cable sealing structure 10F is positioned on topof another cable sealing structure 10G to create a complete seal aboutthe telecommunications cable 26. The cable sealing structures 10F and10G can be identical or different. In the example shown, the cablesealing structures 10F, 10G each have the same reinforcing structure 38Eand gel composition, although alternatives are possible.

While under pressure caused by pressurizing the cable sealing structures10F, 10G about the telecommunications cable 26, portions of thereinforcing structure 38E positioned generally under thetelecommunications cable 26 can collapse. Other portions of thereinforcing structure 38E surrounding the telecommunications cable 26can be strategically positioned or oriented to move the gel within thecable sealing body 78 to allow the gel to fill in spaces (e.g., voids,openings, the eye-shape area, triple points) surrounding thetelecommunications cable 26. That is, while in the sealed position andunder pressure, portions of the reinforcing structure 38E can bearranged and configured to move or force the gel into corners or areas(e.g., triple points) surrounding the telecommunications cable 26 tohelp reduce the “eye effect”. As such, a rebound effect for combatingthe “eye effect” can be provided.

The reinforcing structure 38E can also rebound to its pre-deformed shapeproviding an up and down spring elastic load to the gel. In certainexamples, the reinforcing structure 38E can also have anisotropicdeformation characteristics that allow extension in one direction whilelimiting or restricting deformation in other directions.

FIG. 17 shows a reduction in bulging of the gel while under pressure ofthe telecommunications cable 26. In certain examples, the fibers ornon-deformable projecting rib members, etc. of the reinforcing structure38E can help to keep the gel in place such that less bulging of the geloccurs under pressure. As such, the “tent effect” can be reduced.

Turning to FIGS. 18-19, an example spacer fabric 80 is depicted. SpacerFabrics can include two or more separate fabric faces that are knittedindependently and then connected together by a separate filler spacerfiber.

The example spacer fabric 80 can be used as another type of reinforcingmaterial in accordance with the principles of the present disclosure.The spacer fabric 80 can include microfilaments 82 (e.g., fibers, yarns,plastics, threads, strands, etc.) that are held in position betweenfirst and second fabric surfaces 84, 86 (e.g., front and rear fabricsurfaces; top and bottom surfaces). The microfilaments 82 can be madewith a polymeric material, such as, but not limited to, polyester,although alternatives are possible. One example of fabricating a cablesealing structure can be by overmolding the spacer fabric 80 with thegel 36 using, for example, an overmolding process, injection moldingprocess, extrusion process, printing process, etc., althoughalternatives are possible. The spacer fabric 80 can be arranged andconfigured with the gel 36 to provide a cable sealing structure thatcharacterizes the desired anisotropic properties described herein.Details of an example method for fabricating a composite sealingstructure in accordance with the principles of the present disclosurewill be described below.

Referring to FIG. 20, another example spacer fabric 88 is schematicallydepicted. The example spacer fabric 88 can be used as a reinforcingmaterial in accordance with the principles of the present disclosure.The spacer fabric 88 can include interconnecting filaments 91 (e.g.,yarns, fibers, threads, microfilaments, plastics, strands, etc.)positioned between a first textile substrate 90 (e.g., front fabricsubstrate, top fabric layer) and a second textile substrate 92 (e.g.,back fabric substrate, bottom fabric layer). The first and secondtextile substrates 90, 92 can each include warp and weft yarns. Asdepicted, a plurality of interconnecting filaments 91 can extend betweenthe first and second textile substrates 90, 92.

The first and second textile substrates 42, 44 contains a warp direction(machine direction or direction along the length of the roll) and a weftdirection (cross-machine direction, across the width of the roll, andperpendicular to the warp direction). The first and second textilesubstrates 42, 44 can contain unidirectional strengthening fibers in thewarp direction and weft fibers that run the weft direction. The weftyarns are used to stabilize the fabric and keep the warp yarns parallelto each other.

In one example, the first and second textile substrates 90, 92 are awoven textiles with the reinforcing fibers in the warp direction and theweft fibers in the weft direction. Woven fabrics can be used as the warpfibers and are well aligned in the warp direction and held in place.Some woven textiles include plain, satin, twill, basket-weave, poplin,jacquard, and crepe weave textiles. In one example, the woven textile isa plain weave textile. In another example, the woven textile is a lenoweave. In one example, the woven textile contains two or more weavepattern across a width of the first and second textile substrates 90,92, such as a plain weave and a leno weave.

In another embodiment, the first and second textile substrates 90, 92are knit textiles, for example a circular knit, reverse plaited circularknit, double knit, single jersey knit, two-end fleece knit, three-endfleece knit, terry knit or double loop knit, weft inserted warp knit,warp knit, and warp knit with or without a micro-denier face.

In another embodiment, the first and second textile substrates 90, 92are multi-axial textiles, such as a tri-axial fabric (knit, woven, ornon-woven). In another example, the textile is a bias fabric. In anotherembodiment, the textile is a non-woven. The term non-woven refers tostructures incorporating a mass of yarns that are entangled and/or heatfused so as to provide a coordinated structure with a degree of internalcoherency. Non-woven fabrics for use as the textile may be formed frommany processes such as for example, meltspun processes, hydroentanglingprocesses, mechanically entangled processes, stitch-bonded and the like.

The weave pattern used for the first and second textile substrates 90,92 can be any weave pattern known in the art, (e.g., a twill weavepattern, etc.). A twill weave pattern has the advantage of an improvedflatness of the fabric layers. In one example, the 3D woven textilesubstrate can have a symmetric structure, meaning that the weave patternand the number of threads are identical in both the first and secondtextile substrates 90, 92. In certain examples, highly symmetric 3Dtextile substrates can be used where not only the number and the weavepatterns of the threads are symmetric, but also the chemicalcomposition, type, thickness, and strength of the threads are identicalat both sides of the spacer fabric 88.

The thickness of the 3D spacer fabric 88, defined by the distancebetween the outer surfaces of the first and second textile substrates90, 92, may range from 3 mm to 40 mm, more preferably from 8 mm to 25mm, although alternatives are possible.

In one example, a distance of the warp and weft directions may rangefrom 1.0 mm to 5.0 mm, preferably from 2.0 mm to 4.0 mm, and morepreferably from 3.0 mm to 3.5 mm. Each of the weft and warp and spacerthreads can be monofilament threads. These monofilament threads may becomposed of only one thread, although alternatives are possible. Forexample, more than one monofilament thread can be used, e.g. the warpand the spacer thread may be composed of a pair of two monofilamentthreads to be used in the weaving process. Each thread of the pair ofthreads may have of the same type, thickness and composition but thesetwo threads of the pair may be different such as another thickness,chemical composition, mechanical strength.

In certain examples, each of the threads of the spacer fabric 88 mayinclude one or more polymers selected from a polyester, a polyamide, apolyurethane, a poly(meth)acrylate, a polyolefine, a phenolic resin, apolysulfone, a polyether sulfone, a polyether ether ketone, polyetherketone polystyrene, poly para-phenylene sulfide,polytetrafluoroethylene, polyvinylchloride or copolymers thereof; morepreferably a polyester, a polyamide, poly para-phenylene sulfide orpolytetrafluoroethylene; most preferably a polyester or a polyamide. Thepolymer may be a homo-polymer, a co-polymer of at least 2 of thesepolymers or a mixture or blend of these homo- or co-polymers, althoughalternatives are possible.

In other examples, each of the threads of the spacer fabric 88 may be afiber selected from the list of a polyester fiber, a polyamide fiber, apolyacrylic fiber, an oxidized polyacrylic fiber, a polyurethane fiber,a polyolefine fiber, a high molecular weight polyethylene fiber, apara-aramid fiber, a meta-aramid fiber, a polybenzobisthiazole fiber, apolyetheretherketone fiber, a polyether ketone fiber, a polypara-phenylene sulfide fiber, a polytetrafluoroethylene fiber, a carbonfiber, a ceramic fiber, or a high modulus silicon carbide or siliconnitride fiber; a polyester fiber, a polyamide fiber, a polyolefinefiber, a high molecular weight polyethylene fiber, a para-aramid fiber,a meta-aramid fiber or a poly para-phenylene sulfide fiber; a polyesterfiber or a polyamide fiber, although alternatives are possible.

It will be appreciated that the degree of anisotropy may vary byblending various components of either fibers, yarns, plastics, polymers,etc. in a spacer fabric to produce a desired anisotropic characteristicof a composite sealing structure. The desired degree of anisotropy maybe adjusted in this manner in order to provide the preferred propertiesfor a particular application.

Thus, a composite sealing structure can be stronger or stiffer orless-deformable in one direction versus another. In some examples thiscan be accomplished by changing fibers (such as but not limited toproviding fibers of different materials) in warp versus weft directions,and in the Z direction, for example. Thus, strength can be provided inany direction needed.

The reinforcing structures 38, 38A, 38B, 38C, 38D, 38E can form a bondwith the gel of the respective cable sealing bodies 12, 34, 36, 60, 62,68, 72, 78 to help limit movement of the gel in a specific direction. Inone example, the gel can be molded over the reinforcing structures 38,38A, 38B, 38C, 38D, 38E although alternatives are possible. For example,the gel can be injection molded and cured over the reinforcingstructures 38, 38A, 38B, 38C, 38D, 38E. In other examples, the gel canbe extruded around any of the reinforcing structures described herein.In certain examples, the gel can be printed (e.g., three-dimensionalprinting, two-dimensional printing) around any of the reinforcingstructures described herein.

The present disclosure also relates to a method of making the cablesealing bodies 12, 34, 36, 60, 62, 68, 72, 78. The method includes astep of forming a gel that has a spring like characteristics and/or haveanisotropic deformation characteristics. The method can further includea step of respectively embedding the reinforcing structures 38, 38A,38B, 38C, 38D, 38E into the gel of the cable sealing bodies 12, 34, 36,60, 62, 68, 72, 78. In one example, the step of embedding thereinforcing structures 38, 38A, 38B, 38C, 38D, 38E is by an overmoldprocess. In other examples, the step of embedding the reinforcingstructures 38, 38A, 38B, 38C, 38D, 38E is by an extrusion process. Insome examples, the step of embedding the reinforcing structures 38, 38A,38B, 38C, 38D, 38E is by an injection molding process. In certainexamples, the gel can be printed (e.g., three-dimensional printing,two-dimensional printing) around any of the reinforcingstructures/materials described herein.

The present disclosure also generally relates to a method of fabricatinga composite sealing structure 10 that includes a reinforcing structure38 embedded in a gel material (e.g., sealant). In certain examples, thereinforcing structure 38 may include a spring mesh, screen, a member ormembers, rods, threads, filaments, fibers, wires, springs, elasticelements, mesh, fabric, textile, a strand or strands, netting, foam orcellular structure, although alternatives are possible. In otherexamples, the reinforcing structure 38 may include a metal, a polymer,an extrusion, extensible fabric, a 3D textile, a spacer fabric, ananisotropic 3D textile or knitted fabric, a spring, strength members,elastics, a preform three-dimensional structure, although alternativesare possible. The reinforcing structure 38 can include a variety ofmaterials, such as, but not limited to, a braided textiles, woven, ornon-woven textiles, fibers, chopped fibers, yarns, fine metal wires,plastics, glass fibers, foils, foams, mesh, continuous reinforcingelements, discontinuous reinforcing elements, etc. The term “mesh”includes fabrics, cloths, webs, mats, screens, meshes and the like,which may be open, such as in the case of a screen, or closed, such asin the case of a fabric. It will be appreciated that such variety ofmaterials or structures described may be arranged and/or configured aslayered and/or folded stacks.

The reinforcing structure 38 can also be arranged and configured suchthat the composite sealing structure 10 can have any geometry. Asuitable shape may be any desired shape, such as a geometric shape,e.g., a circle, square, rectangle, triangle, or combinations thereof. Incertain examples, the reinforcing structure 38 may be a preformthree-dimensional structure.

In some examples, the terms “anisotropic”, “anisotropy” and grammaticalvariations thereof, can also include more fibers in a desired direction.This can thus include a change of diameter in a fiber over a length ofthe fiber, and/or a change in diameter at any point or section of thefiber; includes change in cross-sectional shape of the fiber; includeschange in density or number of fibers in a volumetric section of thespacer fabric; includes the use of monofilament fibers and ormultifilament fibers in a volumetric section of the spacer fabric; andcan include variations in material and along individual fibers in avolumetric section of the spacer fabric.

One property of a spacer fabric can include an open porous structure.The open porous structure can be filled and/or covered with a gelmaterial described in detail hereinafter, as indicated in FIG. 21. Thegel material used to fill and/or cover the open porous structure, whichhas good adhesion thereto, may be composed of a dry silicone gel.Generally speaking the disclosure composite structures of the presentdisclosure may be achieved by using spacer fabrics of any desired shapeand any desired porous construction. In certain examples, a compositesealing structure may have an open-cell porous structure (e.g., a spongewith an open-cell construction etc.).

In certain examples, a spacer fabric (3D array or scaffold) can beconstructed of any suitable material. For example, various open cellfoam structures may be used as a spacer fabric. In other examples, thespacer fabric can be made of a material that can be formed bythree-dimensional modelling systems such as three-dimensional printingtechniques. This means that for example computer models are easily usedto produce the spacer fabric. It is a convenient method of implementinga method of the present disclosure therefore, to take a model of adesired porous structure, and to create a spacer fabric representing theporous structure using three-dimensional modelling such as printingtechniques. It will be appreciated then that the spacer fabric can becreated to provide a (resultant) substrate structure which will have thedesired porosity (and thus loading) profile. An alternative method is touse cutting techniques, or selective sintering for example selectivelaser sintering (using lasers to selectively sinter target areas), tocreate a three-dimensional scaffold.

In some examples, the spacer fabric may include reinforcing fibers. Bythe term “reinforcing fiber” herein used is meant a substantiallycontinuous or discontinuous fiber used for a fibrous reinforcingmaterial. For example, there can be mentioned a carbon fiber, a glassfiber, an aramid fiber, a basalt fiber, a silicon carbide fiber, a boronfiber, a metal fiber, a polybenzothiazole fiber, a polybenzoxazole fiberand an alumina fiber. The reinforcing filament includes not only amultifilament but also a fiber yarn which is substantially continuous,although constituent single fibers per se are not continuous, such as aspun yarn. An untwisted continuous filament can be used because thestrength and elastic modulus are increased when the fiber is formed intoa composite material. “Fiber”, in this application, can be defined toinclude a monofilament elongated body, a multifilament elongated body,ribbon, strip, fiber, tape, and the like.

In one example, the reinforcing fibers are formed from the listincluding but are not limited to synthetic polymers (e.g., polyolefins),carbon, nylon, aramid, and glass. Synthetic polymers includepolyethylene (including high density polyethylene, low densitypolyethylene, and ultra-high molecular weight polyethylene),polypropylene, polyoxymethylene, poly(vinylidine fluoride), poly(methylpentene), poly(ethylene-chlorotrifluoroethylene), poly(vinyl fluoride),poly(ethylene oxide), poly(ethylene terephthalate), poly(butyleneterephthalate), polyamide, polybutene, and thermotropic liquid crystalpolymers.

An advantage of the disclosed technology is the ability to producecomposite sealing structures with reinforcing members that haveprecisely defined mechanical properties that can be anisotropic (varywith direction). By combining a reinforcing member with a gel material,an advantage of the composite sealing material is that desiredmechanical properties can be achieved for various application needs.Achieving these characteristics can be facilitated using a spacer fabricimpregnated in combination with a gel material. The composite sealingmaterial of the present disclosure is intended for insertion andcompression between adjacent surfaces where sealing may be required. Thecomposite sealing material includes a reinforcing member impregnatedwith a gel material, for example, a dry silicone gel.

In certain examples, the reinforcing member can be made of ananisotropic open cell foam material prepared from a thermoplastic orthermoset matrix. The anisotropic foam can be fabricated into anydesired shape. Such shapes can generally have a square or rectangularshape and can have multiple flat surfaces or faces. In one example, theopen cell anisotropic foam can be a plank, sheet or block of foam asmost processes for preparing open cell anisotropic foam may form thefoam in a plank, sheet or block, although alternatives are possible. Theopen cell anisotropic foam may be a 3-D textile and/or braided textile,although alternatives are possible. The open cell anisotropic foam maybe impregnated with a gel material to form a composite sealingstructure. The composite sealing structure can be free formed. That is,the composite sealing structure can be formed without having any supportcontainer. In certain examples, the foam can be a thermoplastic polymerbased foam, although alternatives are possible.

Referring to FIG. 21, an example method of fabricating a cable sealingstructure 10H that includes an open cell filter foam sheet 100 and gelmaterial 102 is depicted. It will be appreciated that any open structuremay be used. The open cell filter foam sheet 100 may have a honey combconfiguration (e.g., a circular shaped primary cell structure). Thearrangement and configuration of the open cell filter foam sheet 100 canbe such that it does not retain or hold a gaseous substance. The opencell filter foam sheet 100 can include different cell sizes. In oneexample, the cell sizes may range from about 1 mm to about 5 mm,although alternatives are possible.

The open cell filter foam sheet 100 can have a thickness T (see FIG. 22)that may range from about 10 mm to about 35 mm, although alternativesare possible. For example, the thickness T of the open cell filter foamsheet 100 may range from about 10 mm to about 20 mm, more preferablyfrom 15 mm to 25 mm, and most preferably from 20 mm to 25 mm, althoughalternatives are possible.

The method can include a step of slitting the open cell filter foamsheet 100 in any suitable manner to form slitting zones 104 (e.g.,slits). The slitting zones 104 can be configured partially through theopen cell filter foam sheet 100. The slitting zones 104 can be arrangedand configured to provide preferential stretching in a desireddirection.

Turning to FIG. 22, a depth Dp of which the slitting zones 104 areformed can affect the degree of flexibility of the open cell filter foamsheet 100. As depicted, the depth Dp of the slitting zones 104 is notextend entirely through the thickness T of the open cell filter foamsheet 100. In one example, the depth Dp of the slitting zones 104 mayrange from about 5 mm to about 25 mm, although alternatives arepossible. For example, the depth Dp of the slitting zones 104 may rangefrom about 5 mm to about 15 mm, more preferably from about 5 mm to about20 mm, and most preferably from about 10 mm to about 20 mm.

The amount of uncut material U in the open cell filter foam sheet 100may range from about 5 mm to about 30 mm, although alternatives arepossible. For example, the uncut material U may range from about 5 mm toabout 20 mm, more preferably from about 5 mm to about 15 mm, and mostpreferably from about 5 mm to about 10 mm.

The open cell filter foam sheet 100 has a spacing S between the slittingzones 104. The spacing S may range from about 3 mm to about 10 mm,although alternatives are possible. For example, the spacing S betweenthe slitting zones 104 may range from about 3 mm to about 5 mm, morepreferably from about 3 mm to 7 mm, and most preferably from about 5 mmto about 7 mm.

The process of slitting the open cell filter foam sheet 100 may include,but is not limited to, slitting or cutting with mechanically using ascissor, a knife, a blade, ultrasonic slitting, a digital cutter, and ahot knife. In other examples, the open cell filter foam sheet 100 may beslit using a conventional water jet cutter 106, also known as a waterjet or waterjet. Movements of the water jet cutter 106 can be carriedout in order to be able to cut along any desired slitting zones. Aconventional water jet cutter is known as an industrial tool capable ofcutting a wide variety of materials using a very high-pressure jet ofwater, or a mixture of water and an abrasive substance. The terms purewaterjet and water-only cutting refer to waterjet cutting without theuse of added abrasives, often used for softer materials such as rubber.

In certain examples, an open cell filter foam sheet 100A can bepre-compressed as shown in FIG. 23. In this example, the open cellfilter foam sheet 100A is pre-compressed prior to being impregnatingwith a gel. In the depicted example, the open cell filter foam sheet100A is pre-compressed to obtain more flexibility in one direction andprovide anisotropic characteristics in accord with the presentdisclosure. The pre-compressed open cell filter foam sheet 100A iscompressed in one direction, although alternatives are possible. Forexample, the pre-compressed open cell filter foam sheet 100A can becompressed in two directions. The open cell filter foam sheet 100A wouldbe stretchable in the direction of compression.

Although the example pre-compressed open cell filter foam sheet 100A isdepicted without the slitting zones 104, it will be appreciated that thepre-compressed open cell filter foam sheet 100A may include the slittingzones 104.

In one example, the pre-compressed open cell filter foam sheet 100A canbe compressed at least 20%, 30%, or 40% by length. In other examples,the pre-compressed open cell filter foam sheet 100A can be compressed atleast 33% (e.g., from about 150 units in length to about 100 units inlength), at least 50% (e.g., from about 200 units in length to about 100units in length), or at least 200% of its original length, althoughalternatives are possible. In certain examples, the pre-compressed opencell filter foam sheet 100A can be compressed from about 150 units inlength to about 100 units in length. In still other examples, thepre-compressed open cell filter foam sheet 100A can be compressed fromabout 200 units in length to about 100 units in length. In certainexamples, the pre-compressed open cell filter foam sheet 100A can becompressed at least 20%, at least 25%, at least 30%, at least 35%, atleast 40%, at least 45%, or at least 50%.

The example open cell filter foam sheet 100 or the examplepre-compressed open cell filter foam sheet 100A can be embedded with agel 102 that has a low hardness. The gel 102 can be a dry silicone gelthat is applied over the open cell filter foam sheet 100 and thepre-compressed open cell filter foam sheet 100A to substantiallycompletely and uniformly impregnate the open cell filter foam sheet 100and the pre-compressed open cell filter foam sheet 100A with the gel 102to produce the composite sealing structures 10H, 10I. Once the gel 102is cured, it can hold the pre-compressed open cell filter foam sheet100A in the compressed state to provide the anisotropic properties inaccordance with the principles of the present disclosure.

The gel 102 may be applied to the open cell filter foam sheet 100 andthe pre-compressed open cell filter foam sheet 100A by hand usingbrushes, rollers, or similar tools or applied by impregnating using amachine, for example, where the open cell filter foam sheet 100 and thepre-compressed open cell filter foam sheet 100A are submerged in a bath.The tasks of embedding the open cell filter foam sheet 100 and the opencell filter foam sheet 100A with a gel material can be accomplished in anumber of ways. For example, by molding, extrusion, spinning,calendaring, and coating, although alternatives are possible. In someexamples, the gel material can be poured over the open cell filter foamsheet 100 and the pre-compressed open cell filter foam sheet 100A atroom temperature to fill in the open cell filter foam sheet 100 and thepre-compressed open cell filter foam sheet 100A.

The dry silicone gel will not melt the structures of the open cellfilter foam sheet 100 and the pre-compressed open cell filter foam sheet100A. The pre-compressed open cell filter foam sheet 100A maintains itssame original shape that was formed prior to being impregnated with thedry silicone gel. The dry silicone gel can be four times softer thanother gels. Silicone or polyurethane gels can provide an advantage ofhaving a very low viscosity prior to curing, which can help to make iteasier to fill openings in the reinforcement structure while not meltingthe reinforcement structure. The anisotropic properties of the open cellfilter foam sheet 100 and the pre-compressed open cell filter foam sheet100A allow softer gels to be used. Once the gel is cured, thepre-compressed open cell filter foam sheet 100A can be held in thepre-compressed state.

Various other methods of applying a dry silicone gel to impregnate theopen cell filter foam sheet 100 or the pre-compressed open cell filterfoam sheet 100A may be employed. In some examples, the pre-compressedopen cell filter foam sheet 100A may be pre-compressed and placed in amold (not shown) to be filled with a dry silicone gel while in the moldto produce a composite sealing structure. The mold can be arranged andconfigured to hold the pre-compressed open cell filter foam sheet 100Ain the pre-compressed state. The composite sealing structure can be usedas a seal. In some examples, the composite sealing structure may beheated to make the composite softer and stretchable prior to being usedas a seal. In some examples, a vacuum may be used on the mold to degasthe mold contents and burst any gas or air bubbles remaining in the moldcontents.

In certain examples, a template or mold (not shown) can be positioned ona substrate (faceplate or baseplate, plastic, peelable protective layer,for example). The open cell filter foam sheet 100 or the pre-compressedopen cell filter foam sheet 100A therein can be covered with a drysilicone gel as previously described to produce a composite sealingstructure. Once the dry silicone gel is cured, the gel can hold the opencell filter foam sheet 100A in the pre-compressed state. Whereafter, themold can be removed leaving the composite sealing structure secured tothe substrate. The mold can be easily removed from around the compositesealing structure without adversely effecting the adhesion between thecomposite sealing structure and the substrate.

In some examples, additional substrates or carriers can be provided inthe mold along with the open cell filter foam sheet 100 or thepre-compressed open cell filter foam sheet 100A. FIG. 24 depicts anexample substrate 108 (e.g., a hard or compressible substrate) that canbe combined with the pre-compressed open cell filter foam sheet 100A, oreven with the open cell filter foam sheet 100, to obtain gel insertsthat each have an integral substrate (e.g., formed in one seamlesspiece). A dry silicone gel may be used to bond the substrates to theopen cell filter foam sheet 100 or the pre-compressed open cell filterfoam sheet 100A by adding (e.g., casting, printing, pouring, dipping,molding, etc.) the gel into the open cell filter foam sheet 100 or thepre-compressed open cell filter foam sheet 100A, although alternativesare possible. In other words, the open cell filter foam sheet 100 andthe substrate 108 or the pre-compressed open cell filter foam sheet 100Aand the substrate 108 are a single, integrally molded piece, althoughalternatives are possible. As a result, a two layer structure ofreinforced gel on top of a substrate can be formed.

The substrate or substrates could function as an exterior containmentlayer, sheet, or carrier, which can be made of plastic, rubber foam,metal, or other material. In other examples, the substrate or substratesmay include a connection interface for connecting (e.g., snap-fitting)to another interface (e.g., an interface in a housing).

In certain examples, the substrate can also be a pealable protectivelayer. The pealable protective layer can be provided to facilitatehandling of the composite sealing structure (e.g., combined product ofthe dry silicone gel and the open cell filter foam sheet) or to protectthe composite sealing structure from contamination.

Referring to FIG. 24, the substrate 108 is provided at one side of thepre-compressed open cell filter foam sheet 100A to form a compositesealing structure 10J with gel or the pre-compressed open cell filterfoam sheet 100A can be sandwiched between two substrates 108. In otherexamples, the substrate 108 may also have elastic characteristics (e.g.,rubber foam, spring steel) so as to be capable of storing potentialenergy that is applied to the composite sealing structure as springforce when the composite sealing structure 10J is used as a seal such asa cable seal. The substrate 108 can be cut to shape along with thepre-compressed open cell filter foam sheet 100A such that the two can becut at the same time by mechanical, waterjet, or any other suitablecutting method.

Following impregnation, after about 1 hour or less; preferably, afterabout 45 minutes or less, the cable sealing structures 10H, 10I, 10J maybe divided along cut lines 110 to form a plurality cable sealingstructures 10H, 10I, 10J (e.g., sealing inserts) that each have astretch dimension or a preferential stretch orientation 112 that istransverse or perpendicular to the slitting zones 104 of the compositesealing structure 10H. In one example, the water jet cutter 106 may beused to divide the composite sealing structure, although alternativesare possible.

In one example, the method can include a step of dividing the open cellfilter foam sheet 100 of the composite sealing structure 10H into 5millimeters (mm) wide strips perpendicular to the slitting zones 104,although alternatives are possible. For example, the open cell filterfoam sheet 100 can be divided into widths of at least 1 mm, 2 mm, 3 mm,4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, or other widths thatcorrelate to a desired application need. The widths of the open cellfilter foam sheet 100 or the pre-compressed open cell filter foam sheet100A may be custom made and determined per the structure to be sealed ormay vary in widths for a given structure to seal different zones in agiven structure. The open cell filter foam sheet 100 or thepre-compressed open cell filter foam sheet 100A can have a width ofbetween about 2 and 20 millimeters, more preferably between about 4 and8 millimeters.

As depicted, the open cell filter foam sheet 100 and the pre-compressedopen cell filter foam sheet 100A are cut along one direction. As such,the open cell filter foam sheet 100 no longer has any strength in thedirection opposite to the slitting zones 104. Also, the pre-compressedopen cell filter foam sheet 100A no longer has any stretch in thedirection opposite to the direction of compression. The anisotropiccable sealing structures 10H, 10I, 10J can be fabricated into anydesired shape or size. Such shapes generally have a square orrectangular shape and have multiple surfaces. In one example, theanisotropic composite sealing structures can be arranged as blockinserts for sealing. It will be appreciated that the method offabricating cable sealing structures can be applied to any of theprevious cable sealing structures 10 _(A-J) described herein.

Another aspect of the present disclosure relates to a method of making acomposite sealing structure with anisotropic behavior. The method caninclude the steps of 1) constructing a spacer member that is adapted todefine an open porous structure of the anisotropic composite seal; 2)slitting the spacer member to provide multiple slits; 3) impregnatingthe spacer member with a gel material; and 4) dividing the gelimpregnated spacer along cut lines transverse to the slits to form aplurality of cable sealing inserts with an open porous structure definedby the spacer member. The method may also include the steps ofpre-compressing the open porous structure prior to being impregnatedwith gel. The method may also include the steps of providing a substrateat one side of the composite seal or sandwiching the composite seal canbetween two substrates. The substrates can be bonded to the compositeseal by the gel material. Thus, the composite seal can be supportedbetween a pair of supporting substrates without applying pressure. Themethod may further include a vacuum step to remove gas or air bubblesfrom the impregnated structure. It will be appreciated that this methodcan also apply to any of the previous cable sealing structures 10 _(A-J)described herein.

The present disclosure also relates to methods for printing any of thecable sealing structures described herein by using a three dimensional(3-D) printer 114.

Turning to FIG. 25, a schematic perspective view of the printer 114 isshown. The printer 114 may be, for example, a drop-on-demand (DOD)printer where a material is ejected as a plurality of droplets through anozzle and the droplets can coalesce together to create a continuouslayer. The printer 114 may be a printer other than a DOD printer, suchas an extrusion printer or a printer which uses other printingtechnology. The printer 114 can include first and second print headnozzles 116, 118 (e.g., first and second dispensing nozzles, extrusionheads) through which material is printed (e.g., extruded) under pressureto fabricate a 3D cable sealing structure 10K, which is depicted as agel block.

In one example, the cable sealing structure 10K can be printed in alayer-by-layer manner from the first and second print head nozzles 116,118 where the layers of the cable sealing structure 10K grow along thevertical y-axis. In certain examples, the first and second print headnozzles 116, 118 are each arranged and configured to dispense materialseparately.

In certain examples, the layers of the cable sealing structure 10K canbe printed to form a “free-standing” structure. As used herein, the term“free-standing,” is defined as being self-supporting such that layers ofthe cable sealing structure 10K remain intact when dispensed without theneed for a container or other lateral support member.

The extruded material can be the gel material 102 that can be printed toform a first printed gel layer of the cable sealing structure 10K. Afterthe first printed gel layer of the cable sealing structure 10K isprinted, a reinforcing material 38F (e.g., a reinforcing material of thetype previously described) can be printed such that a first printedreinforcing material layer can be disposed over the first printed gellayer. Subsequently, a second printed gel layer can be printed with aprinter over the first printed reinforcing material layer to form asecond printed gel layer. Thereafter, a second printed reinforcingmaterial layer can be disposed over the second printed gel layer. Thisprocess can be repeated layer by layer until the desired architecture isachieved. In one example, the first printed reinforcing material layercan be parallel, perpendicular, or oriented crosswise in relation to thefirst printed gel layer. That is, the first printed reinforcing materiallayer can be disposed parallel, perpendicularly, diagonally ortransversely over the first printed gel layer to create a latticestructure layer by layer.

In one example, the gel 102 can be dispensed independently from thereinforcing material 38F, although alternatives are possible. The firstprint head nozzle 116 is shown dispensing the gel 102 and the secondprint head nozzle 118 is shown dispensing the reinforcing material 38F,although alternatives are possible. The first and second print headnozzles 116, 118 each include a respective pair of rollers 120A, 120B,122A, 122B that are arranged and configured to feed a component, the gel102 or the reinforcing material 38F, through the first and second printhead nozzles 116, 118, respectively. In certain examples, the rollers120A and 122A rotate in a clockwise direction and rollers 120B and 122Brotate in a counterclockwise direction, although alternatives arepossible.

Printing the gel 102 can include feeding the gel 102 to enter one end124 of a first flow passage 126 of the first print head nozzle 116 thathas a first discharge orifice 128 on another end 130. The gel 102 canexit through the first discharge orifice 128. Printing the reinforcingstructure 38F can include feeding the reinforcing structure 38F to enterone end 132 of a second flow passage 134 of the second print head nozzle118 that has a second discharge orifice 136 on another end 138. Thereinforcing structure 38F can exit through the second discharge orifice136. In certain examples, the gel 102 and the reinforcing structure 38Fcan be fed together or separately through a single flow passage of asingle print head nozzle. In certain examples, the gel 102 and thereinforcing structure 38F can exit together or separately through asingle discharge orifice of the single print head nozzle.

A pump (not shown) can responsively feed the gel 102 and the reinforcingstructure 38F from respective supplies to inlets 140A, 140B of a printhead nozzle (for example see FIGS. 27C-27E) , and controls the rate ofextrusion of the gel 102 and the reinforcing material 38F from the printhead nozzle. By controlling the rate of extrusion while moving the printhead nozzle in a pattern determined by desired CAD (computer-aideddesign) data, a cable sealing structure (e.g., a three-dimensionalobject, which resembles a CAD model) can be created.

In certain examples, the reinforcing structure 38F may include athermoplastic, braided textiles, woven, or non-woven textiles, fibers,yarns, strings, rubbery filament, fine metal wires, plastics, glassfibers, foils, foams, a biasing member, such as a spring, strengthmembers, fabrics, anisotropic 3D textiles or knitted fabrics, a preformthree-dimensional structure, elastics, extensible fabrics, etc.,although alternatives are possible.

The reinforcing structure 38F can be organized in a desired directionsuch that the reinforcing structure 38F becomes embedded within the gel102 and forms a bond with the gel 102. Placement and organization of thereinforcing structure 38F embedded in the gel 102 can help to limitmovement of the gel 102 in a specific direction in order to provide thecable sealing structure 10F with a desired anisotropic behavior. Assuch, the reinforcing structure 38F helps to internally constrain thegel 102 to assist in gel containment and in certain cases limit tenteffect.

Still referring to FIG. 25, the anisotropic behavior of the cablesealing structure 10K can be controlled by controlling the motion and/ordirection of the first and second print head nozzles 116, 116 of theprinter 114, although alternatives are possible. For example, theprinter 114 can be moved left and right such that the first and secondprint head nozzles 116, 118 can lay down respective layers of the gel102 and the reinforcing structure 38F as desired. As such, the firstprint head nozzle 116 can be used to determine where the gel 102 isapplied and the second print head nozzle 118 can be used to determinewhere the reinforcing structure 38F is applied. It will be appreciatedthat the printer 114 may also include a third print head nozzle (notshown) to print a different type of filament than the reinforcingstructure 38F used.

In certain examples, the reinforcing structure 38F can be dispensedwithin a range of 2 mm to 6 mm apart, although alternatives arepossible. The gel 102 can be dispensed within a range of 1 mm to 3 mm tofill between the reinforcing structure 38F, although alternatives arepossible. The first and second print head nozzles 116, 118 of theprinter 114 can oscillate (e.g., back and forth, to and from, etc.)until a length of the cable sealing structure 10K is equal to a heightof the cable sealing structure 10K, although alternatives are possible.

In certain examples, the first and second print head nozzles 116, 118 ofthe printer 114 can be moved up and down generally along the Y-axisand/or left and right generally along an X-axis to steer anisotropicbehavior when forming the cable sealing structure 10K as desired. Thegel 102 and the reinforcing structure 38F can be dispensed from thefirst and second print head nozzles 116, 118, respectively in afront-to-back or left-to-right orientation as determined by the movementof the first and second print head nozzles 116, 118. In other examples,the cable sealing structure 10K may be formed by printing layers of thereinforcing structure 38F in both a left-to-right orientation and afront-to-back orientation to provide reinforcement in both X and Ydirections. As such, the strength of the cable sealing structure 10Kwould coincide with the direction of the reinforcing structure 38F.

When the reinforcing structure 38F is printed in a left-to-rightorientation, the resulting cable sealing structure 10K would be harderto stretch or deform (e.g., more rigid) in the left-to-rightorientation. When the reinforcing structure 38F is printed in afront-to-back orientation, the resulting cable sealing structure 10Kwould be harder to stretch or deform (e.g., more rigid) in thefront-to-back orientation. Thus, 3D printing the cable sealing structure10K can achieve the desired anisotropic behavior. Also, a variety ofgeometries and designs can be achieved by 3D printing the cable sealingstructure 10K. For example, the cable sealing structure 10K may beformed of any shape, (e.g., circular, rectangular, oval, square,triangular, sphere, cube, octahedron, and any other shape or combinationthereof).

In certain examples, a rubbery filament (e.g., rubbery wire, elasticfilament) may be used in combination with the gel 102 for addedelasticity. The rubbery filament may have a hardness in the range of 30to 80 Shore 000 to provide flexibility or extra elasticity, althoughalternatives are possible. In certain examples, the rubbery filament canbe stiffer than the gel 102. In some examples, a harder material (e.g.,hard rubber or plastic) may be used in combination with the gel,although alternatives are possible. The harder material may also be 3Dprinted through a separate print nozzle and can be melted or undergo achemical curing reaction. The harder material may be combined with a gelmaterial dispensed through a separate gel printing nozzle to form acable sealing structure, although alternatives are possible.

The temperature of the first print head nozzle 116 can be controlledaccurately in order to dispense the gel 102 in a molten or liquid state.For example, the gel 102 may be dispensed at a temperature within 180°C. to 200° C., although alternatives are possible.

In certain examples, the cable sealing structure 10K can be printedwithin a container (not shown), for example when the viscosity of thegel 102 is too low (e.g., a liquid) such that the cable sealingstructure 10K would be non-self-supporting and would collapse absent thecontainment. In such an example, the container may be placed on a flatsurface or table to dispense the gel 102 and the reinforcing structure38F therein. In order to control the anisotropic behavior of the cablesealing structure 10K, the container or the table may be moved in alldirections (e.g., up, down, front, back, left, and/or right) whilekeeping the first and second print head nozzles 116, 118 stationary orfixed.

In certain examples, the cable sealing structure 10K may be formed on apolymer sheet (not shown), such as, but not limited to, polypropylene.The polymer sheet can stick to the gel 102 at a temperature within 180°C. to 200° C., although alternatives are possible, in order to build thecable sealing structure 10K layer by layer. Once the cable sealingstructure 10K is built, the polymer sheet is no longer needed and can beremoved. In certain examples, the cable sealing structure 10K may befree formed without any support.

In one example, the thickness of the layers of the cable sealingstructure 10K can be within 2 mm to 8 mm, although alternatives arepossible. The thickness of the layers can depend on the viscosity of thegel 102 and how quickly it may dry. For example, the cable sealingstructure 10K may include 21 layers (e.g., folds) with a total thicknessof about 125 mm or 5 inches. As such, each layer or fold would have athickness of about 6 mm. It will be appreciated that the thickness layermay vary with other embodiments. For example, the total thickness of thecable sealing structure 10K can be about 130 mm. The layers of the cablesealing structure 10K can have a width within 2 mm to 7 mm. Certainseals of the type disclosed herein can include at least 5, 10, 15 or 20layers each applied one on top of the other.

Referring to FIG. 26, a schematic perspective view of a different printhead system 142 usable with a printer is shown. In the example depicted,the print head system 142 has a single print head nozzle 144 that can beused to form a cable sealing structure 10L. Similar to the printer 114described with reference to FIG. 25, the print head system 142 cansimultaneously extrude gel 102 and the reinforcing structure 38F tocontrol deformation behavior by controlling the motion or direction ofmovement of the print head nozzle 144. Similar to the printer 114described above, the print head nozzle 144 of the print head system 142can be moved in all directions (e.g., along the x-axis, y-axis, andz-axis) front-to-back, up and down, left-to-right etc. to form the cablesealing structure 10L with a desired geometric shape having anisotropicbehavior. As such, the gel 102 and reinforcing structure 38F can bedispensed in a direction or orientation of the print head nozzle 144. Inother examples, a support structure or table can be moved to obtain acable sealing structure that has anisotropic behavior and is capable ofhaving multiple geometries.

In the example depicted, printing the gel 102 includes feeding the gel102 to enter one end 146 of a first flow passage 148 of a first feeder150 and printing the reinforcing structure 38F includes feeding thereinforcing structure 38F to enter one end 152 of a second flow passage154 of a second feeder 156.

Referring to FIG. 27, a schematic perspective view of the print headnozzle 144 is depicted. The first and second flow passages 148, 154 canboth enter the print head nozzle 144 to feed the gel 102 and thereinforcing structure 38F, respectively. The print head nozzle 144 canhave a single discharge orifice 158 on another end 160. The gel 102 andthe reinforcing structure 38F can both exit together through the singledischarge orifice 158.

In the example depicted, the reinforcing structure 38F can be a discreteor single fiber that can be pulled through the gel 102 when both the gel102 and the reinforcing structure 38F are dispensed through the singledischarge orifice 158. The reinforcing material can include a continuousbead, thread, or other shape of uninterrupted, interconnected materialor can be formed of a plurality of separate non-continuous pieces (e.g.,a fiberglass chop or other materials).

As the gel 102 and the reinforcing structure 38F are combined in theprint head nozzle 144, the gel 102 can take the form of the reinforcingstructure 38F. The gel 102 can be a soft conformable material arrangedand configured to be flexible around the reinforcing structure 38F asthe reinforcing structure 38F is pulled through the gel 102.

The print head nozzle 144 is generally vertical and can be moved in alldirections (e.g., along x, y, and z axis). As described herein, themovement of the print head nozzle 144 can dictate where the reinforcingstructure 38F is applied. The reinforcing structure 38F can be placedindividually along the z-axis that corresponds to the cable pass-throughdirection D to prevent deformation along the cable axis (e.g., z-axis).As such, the reinforcing structure 38F can be placed parallel with thecable axis. Similarly, if the reinforcing structure 38F is printed alongthe x-axis, reinforcement will be in the x direction. If the reinforcingstructure 38F is printed along the y-axis, reinforcement will be in theydirection. It will be appreciated that printing layers of reinforcingstructure 38F can be fabricated in both x and y directions.

The gel 102 and reinforcing structure 38F can flow onto a printing tableas one combined flow of material to form the cable sealing structure10L. In one example, the combined flow of material can flow into asupport container to form the cable sealing structure 10L, althoughalternatives are possible. For example, the combined flow of materialcan be free formed. That is, the cable sealing structure 10L can beformed without having any support container, as described herein.

FIG. 27A shows the reinforcing structure 38F chopped and co-dispensedwith the gel 102. In this example, the chopped reinforcing structure 38Fmay include fibers, knitted structures, yarns, filaments, strengthmembers, elastics, and/or threads, although alternatives are possible.In certain examples, the reinforcing material may compose of acombination of different filaments.

The chopped reinforcing structure 38F mixes with the gel 102 as shown inFIG. 27B and flows through the print head nozzle 144 and out the singledischarge orifice 158 to form the cable sealing structure 10L. The gel102 can be heated in a controlled manner to cause the gel 102 to meltwhich may allow the reinforcing structure 38F to mix and sink (e.g.,embed) into the gel 102. The combined mixture of the gel 102 and thereinforcing material 38F can be dispensed in whatever orientation theprint head nozzle 144 is directed. The layers of reinforcing structure38F and gel 102 aligning in a manner that forms the desired anisotropicproperties of the cable sealing structure 10L.

The cable sealing structure 10L can be built layer-by-layer as the printhead nozzle 144 oscillates back-and-forth, left-to-right, up-and-down,etc., as desired. Various geometric shapes of the cable sealingstructure 10L can be fabricated using a 3D printer. The various layersthat make up the cable sealing structure 10L can be printed parallel,perpendicular, or oriented crosswise with respect to one another (bestshown in FIGS. 27C-27D). That is, the layers can be disposed parallel,perpendicularly, diagonally, or transversely over another layer tocreate a lattice structure layer-by-layer. The oscillation directionsD₅, D₆ or orientation of the print head nozzle 144 respectively shown inFIGS. 27C-27D can dictate the direction and orientation of the layersforming the cable sealing structure 10L. It will be appreciated thatother print orientations may be used to fabricate the cable sealingstructure 10L.

Referring to FIG. 27E, the combined mixture of the gel 102 and thereinforcing structure 38F can be extruded or dispensed directly insideof a first housing 162 piece (e.g., bottom piece) of another enclosure14 a to form a seal member 164. It will be appreciated that the sealmember 164 can be dispensed in a second housing piece (not shown) (e.g.,top piece) that can be arranged and configured to mate (e.g., connect,attach) with the first housing piece 162 to form the enclosure 14 a. Theseal member 164 can be applied in containment spaces (e.g., cavities) ofthe enclosure 14 a defined by sidewalls 166 and end walls 168 thereof.In other examples, the seal member 164 having a composition of both thegel 102 and the reinforcing structure 38F can be in the form ofpre-shaped pieces, which can be located in the containment spaces of theenclosure 14 a, although alternatives are possible. For example, a sealstructure may be printed to form a perimeter sealing region of anenclosure in a perimeter channel and another seal structure may beprinted to form a cable sealing region in a larger cable sealing cavity.The cable sealing cavity and the perimeter channel can be in fluidcommunication with each other such that both of the seal structuresprinted therein are in fluid communication.

The structures of the seal structures (e.g., sealant blocks) can bedifferent in the cable sealing region and the perimeter sealing regionof the enclosure. For example, the cable sealing region may includesealant and reinforcement and the perimeter seal may or may not includereinforcement. The gel in the cable sealing region may have a higher orlower durometer as compared to the perimeter sealing region. Conformalprinting techniques can be used for either or both regions.

In the cable sealing region, pre-defined notches or openings or othercontoured shapes can be printed into the printed seal structures tocorrespond to sealed cable pass through locations at a cable sealinginterface of the seal structures. In other examples, pre-defined notchesor openings may be omitted and a flat, non-contoured sealing surface maybe used at the cable sealing interface of the sealing interface of theseal structures. In certain examples, a cable sealing structure 10 canbe pre-shaped with an opening or surface where no material is to beprinted or placed. As such, a pre-defined location can be formed in thecable sealing structure 10 that may be arranged and configured toreceive the telecommunications cable 26 and form a complete sealthereabout.

Similarly, a 3D printer can be used to dispense the reinforcingstructure 38F in any specific orientation, in any discrete location, inany geometric shape, within the gel 102 to achieve the desiredanisotropic behavior and geometry of the cable sealing structure 10L.

Turning now to FIG. 28, another example cable sealing structure 10M isformed using 3D printing. In the depicted example, a schematicperspective view of a print head nozzle 170 is shown with gel 102 and atextile strip 172 (e.g., iso filaments, woven, non-woven, braidedtextile, tape, etc.) being respectively feed through separate first andsecond entry ports 174, 176. The gel 102 can be fed through a feeder 178that can define a flow passage 180. The textile strip 172 can bearranged and configured such that a desired orientation of reinforcingmaterials is already formed therein. As such, the cable sealingstructure 10M can be formed layer-by-layer by co-dispensing the gel 102and textile strip 172 to achieve a desired geometric shape withanisotropic behavior.

In one example, the gel 102 can be extruded (e.g., extrusion printed)onto the textile strip 172 when the gel 102 and the textile strip 172are combined inside the print head nozzle 170. It will be appreciatedthat other printing techniques may be used, such as, but not limited to,printing single fibers in an orientation similar to the nozzle. In theexample depicted, the combined gel 102 and textile strip 172 can bedispensed through a single exit port 182 of the print head nozzle 170 asa gel covered textile strip 184. As a layer of the gel covered textilestrip 184 exits the print head nozzle 170, the layers can melt (e.g.,fuse) together to form one solid block of the cable sealing structure10M. As such, the cable sealing structure 10M can be built by stackingthe gel covered textile strip 184 layer-by-layer until, for example, alength of the cable sealing structure 10M equals a height of the cablesealing structure 10M, although alternatives are possible. The textilestrip 172 can be arranged and configured to not stretch in the longdirection, while the gel 102 can be arranged and configured to stretchin the long direction, although alternatives are possible.

The thickness of the gel 102 can be within 1 mm to 2 mm on each side ofthe textile strip 172, although alternatives are possible. For example,the gel 102 can be within 3 mm to 4 mm thick on each side of the textilestrip 172. The overall thickness of the gel 102 covering the textilestrip 172 can be within 2 mm to 4 mm, although alternatives arepossible.

In certain examples, the gel 102 can be in liquid form when it isextruded. That is, the gel 102 can be extruded at a temperature similarto thermoplastics. As such, the gel 102 can be heated to a processtemperature of 200° C. to 250° C. where the gel 102 melts and later beallowed to cool to solidify. In certain examples, the gel 102 can be areactive type gel that has a chemical mixture including reactants thatcrosslink, which can allow for more time options on when the gel 102 canbe processed before it starts to solidify. Certain silicon andpolyurethane gels can be processed at room temperature. The reaction canbe accelerated by heating the gel 102 to 90° C. In certain examples, thetemperature can be increased up to 200° C. to speed up curing. As such,modifying speed of process can be achieved by varying the chemistry ofthe gel and varying the processing temperature, although alternativesare possible. In other examples, the gel 102 can be cured usingultraviolet (UV) light source.

In certain examples, the print head nozzle 170 can be moved to create azigzag structure of the textile strip 172. As described herein, thecable sealing structure 10M can be made by dispensing the gel coveredtextile strip 172 into a support structure or container, althoughalternatives are possible. For example, the cable sealing structure 10Mcan be made by free-forming the gel covered textile trip 172 withoutusing any containers as support.

In one example, gel sealing can be used in conformal 3D printing. Insuch examples, gel can be applied onto a curved surface or other surfacehaving three dimensional shapes. The gel can be printed to conform to asurface that may be a 3D object. For example, the gel can be printedonto a 3-dimensionally shaped surface that may include curved lines. Incertain examples, the gel can be printed onto a molded part or onto asubstrate directly in a closure housing.

The cable sealing structures 10 _(A-M) described herein can befabricated layer-by-layer (e.g., one at a time) in flat, parallel planesor curved conformal layers.

The present disclosure also relates to a method of making a seal thatincludes the steps of: 1) feeding a gel material to enter one of a firstflow passage of a first dispensing nozzle having a first dischargeorifice on another end; 2) feeding at least one filament material toenter one end of a second flow passage of a second dispensing nozzlehaving a second discharge orifice on another end; 3) printing alternatelayers of the gel material and the at least one filament material; and4) during the dispensing step, moving the first and second dispensingnozzles in a plane defined by first and second directions to form acable sealing structure. In other examples, the gel material and the atlast one filament material may be combined inside a single dispensingnozzle.

The present disclosure also relates to a method of making the cablesealing structures 10 _(A-M). The method includes a step of forming agel that has a construction with anisotropic deformationcharacteristics. The method can further include a step of respectivelyembedding the reinforcing structures 38 _(A-F) into the gel ofrespective cable sealing structures 10 _(A-M). In one example, the stepof embedding the reinforcing structures 38 _(A-F) is by 3D printing. Inother examples, the step of embedding the reinforcing structures 38_(A-F) is by an overmold process. In certain examples, the step ofembedding the reinforcing structures 38 _(A-F) is by an extrusionprocess. In some examples, the step of embedding the reinforcingstructures 38 _(A-F) is by an injection molding process.

Some Selected Characterizations

The following characterizations are indicative of features andtechniques according to the present disclosure that relate to: a cablesealing structure, and a method of making a cable sealing body for usein telecommunications enclosure. In this summary, some selected, summarycharacterizations of the teachings herein are provided. The list ofcharacterizations is not meant to be exhaustive. 1. A cable sealingstructure characterized by: a cable sealing body including a gel; and atleast one reinforcing structure embedded in the gel; wherein as thecable sealing structure is deformed to form a seal, the at least onereinforcing structure elastically deforms to apply an elastic load tothe cable sealing body. 2. The cable sealing structure ofcharacterization 1 wherein: the at least one reinforcing structure isconfigured to rebound to its pre-deformed shape. 3. The cable sealingstructure of characterization 1 wherein: the cable sealing body hasanisotropic deformation characteristics. 4. The cable sealing structureof characterization 1 wherein: the cable sealing body includes anx-dimension that extends along an x-axis, a y-dimension that extendsalong a y-axis and a z-dimension that extends along a z-axis, whereinthe z-axis corresponds to a cable pass-through direction, and whereinthe cable sealing body is less deformable along the z-axis as comparedto at least one of the x and y axes. 5. The cable sealing structure ofcharacterization 4 wherein: the cable sealing body is less deformablealong the z-axis as compared to both the x and y axes. 6. The cablesealing structure of characterization 4 wherein: the at least onereinforcing structure is oriented and positioned in the cable sealingbody such that the cable sealing body is more deformable along thex-axis as compared to at least one of the y and z axes. 7. The cablesealing structure of characterization 1 wherein: the cable sealing bodyincludes a plurality of separately discrete reinforcing structures. 8.The cable sealing structure of characterization 7 wherein: the pluralityof separately discrete reinforcing structures are generally alignedalong the z-axis. 9. The cable sealing structure of characterization 8wherein: the cable sealing body is less deformable along the z-axis ascompared to both the x and y axes. 10. The cable sealing structure ofcharacterization 1 wherein: the at least one reinforcing structure isembedded into the cable sealing body such that the at least onereinforcing structure has a shape that is generally zig-zag. 11. Thecable sealing structure of characterization 1 wherein: the at least onereinforcing structure is a preform three-dimensional structure that isembedded into the cable sealing body, the preform three-dimensionalstructure providing a self-supporting shape of the at least onereinforcing structure. 12. The cable sealing structure ofcharacterization 1 wherein: the at least one reinforcing structure has awidth no greater than a width of the cable sealing body. 13. The cablesealing structure of characterization 4 wherein: the x-axis defines alength axis of the cable sealing body, the y-axis defines a height axisof the cable sealing body, and the z-axis defines a depth axis of thecable sealing body. 14. The cable sealing structure of characterization1 wherein: the at least one reinforcing structure is a textile. 15. Thecable sealing structure of characterization 14 wherein: the textile is awoven substrate. 16. The cable sealing structure of characterization 1wherein: the at least one reinforcing structure is a metal. 17. Thecable sealing structure of characterization 1 wherein: the at least onereinforcing structure is a polymer. 18. The cable sealing structure ofcharacterization 1 wherein: the at least one reinforcing structure is aspring. 19. The cable sealing structure of characterization 1 wherein:the at least one reinforcing structure includes strength members. 20.The cable sealing structure of characterization 1 wherein: the at leastone reinforcing structure forms a bond with the gel of the cable sealingbody. 21. A method of making a cable sealing body, the methodcharacterized by a step of: forming a gel having a construction withelastic characteristics. 22. The method of characterization 21 furthercomprising: a step of embedding a reinforcing structure into the gel ofthe cable sealing body. 23. The method of characterization 22 wherein:the step of embedding the reinforcing structure is by an overmoldprocess. 24. The method of characterization 22 wherein: the step ofembedding the reinforcing structure is by an extrusion process. 25. Acable sealing structure characterized by a cable sealing body includinga gel, the cable sealing body having a construction with anisotropicdeformation characteristics. 26. The cable sealing structure ofcharacterization 25 wherein: the cable sealing body includes anx-dimension that extends along an x-axis, a y-dimension that extendsalong a y-axis and a z-dimension that extends along a z-axis, whereinthe z-axis corresponds to a cable pass-through direction, and whereinthe cable sealing body is less deformable along the z-axis as comparedto at least one of the x and y axes. 27. The cable sealing structure ofcharacterization 26 wherein: the cable sealing body is less deformablealong the z-axis as compared to both the x and y axes. 28. The cablesealing structure of characterization 26 wherein: the cable sealing bodyincludes at least one reinforcing member. 29. The cable sealingstructure of characterization 28 wherein: the at least one reinforcingmember is oriented and positioned in the cable sealing body such thatthe cable sealing body is more deformable along the x-axis as comparedto at least one of the y and z axes. 30. The cable sealing structure ofcharacterization 28 wherein: the at least one reinforcing member isoriented and positioned in the gel of the cable sealing body such thatthe cable sealing body is more deformable along the x-axis as comparedto both the y and z axes. 31. The cable sealing structure ofcharacterization 26 wherein: the cable sealing body includes a pluralityof separately discrete reinforcing structures. 32. The cable sealingstructure of characterization 31 wherein: the plurality of separatelydiscrete reinforcing structures are generally aligned along the z-axis.33. The cable sealing structure of characterization 32 wherein: thecable sealing body is less deformable along the z-axis as compared toboth the x and y axes. 34. The cable sealing structure ofcharacterization 28 wherein: the at least one reinforcing member isembedded into the cable sealing body such that the at least onereinforcing member has a shape that is generally zig-zag. 35. The cablesealing structure of characterization 28 wherein: the at least onereinforcing member is a preform three-dimensional structure that isembedded into the cable sealing body, the preform three-dimensionalstructure providing a self-supporting shape of the at least onereinforcing member. 36. The cable sealing structure of characterization28 wherein: the at least one reinforcing member has a width no greaterthan a width of the cable sealing body. 37. The cable sealing structureof characterization 26 wherein: the x-axis defines a length axis of thecable sealing body, the y-axis defines a height axis of the cablesealing body, and the z-axis defines a depth axis of the cable sealingbody. 38. The cable sealing structure of characterization 28 wherein:the at least one reinforcing member is a textile. 39. The cable sealingstructure of characterization 38 wherein: the textile is a wovensubstrate. 40. The cable sealing structure of characterization 28wherein: the at least one reinforcing member is a metal. 41. The cablesealing structure of characterization 28 wherein: the at least onereinforcing member is a polymer. 42. The cable sealing structure ofcharacterization 28 wherein: the at least one reinforcing member is aspring. 43. The cable sealing structure of characterization 28 wherein:the at least one reinforcing member has elastic characteristics. 44. Thecable sealing structure of characterization 28 wherein: the at least onereinforcing member includes strength members. 45. The cable sealingstructure of characterization 28 wherein: the at least one reinforcingmember forms a bond with the gel of the cable sealing body. 46. A methodof making a cable sealing body, the method characterized by a step of:forming a gel having a construction with anisotropic deformationcharacteristics. 47. The method of characterization 46 furthercomprising a step of embedding a reinforcing member into the gel of thecable sealing body. 48. The method of characterization 47 wherein: thestep of embedding the reinforcing member is by an overmold process. 49.The method of characterization 47 wherein: the step of embedding thereinforcing member is by an extrusion process. 50. A method offabricating an anisotropic composite seal for telecommunicationsenclosures, the method characterized by steps of: constructing a spacermember that is adapted to define an open porous structure of theanisotropic composite seal; impregnating the spacer member with a gelmaterial to form a composite sealing structure; and dividing the gelimpregnated spacer along cut lines transverse to the slits to form aplurality of sealing inserts each with an open porous structure, eachone of the sealing inserts having a construction with anisotropicdeformation characteristics. 51. The method of characterization 50wherein: the step of dividing the gel impregnated spacer member is bynon-mechanical, cutting-energy to provide the sealing inserts inprecisely sized portions. 52. The method of characterization 51 wherein:the non-mechanical, cutting-energy providing medium is a high-pressurewater jet. 53. The method of characterization 50 further comprising: astep of slitting the spacer member to provide multiple slits thereinprior to the step of impregnating the spacer member. 54. The method ofcharacterization 50 further comprising: a step of pre-compressing thespacer member prior to the step of impregnating the spacer member. 55.The method of characterization 50 wherein: the step of pre-compressingthe spacer member is performed within a mold. 56. The method ofcharacterization 55 wherein: the step of impregnating the spacer memberis performed while in the mold. 57. The method of characterization 56further comprising: a step of bonding a substrate to the spacer memberwhile inside the mold, the substrate being bonded to the spacer memberusing the gel material. 58. The method of characterization 57 wherein:the composite sealing structure is sandwiched between two substratesprovided in the mold. 59. The method of characterization 57 wherein: thesubstrate is a containment layer that includes a connection interfacefor connecting to another interface in a housing. 60. The method ofcharacterization 57 wherein: the substrate is a peelable protectivelayer to help facilitate handling of the composite sealing structure orfor protecting the composite sealing structure from contamination. 61.The method of characterization 57 wherein: the substrate has elasticcharacteristics for storing potential energy that is applied to thecomposite sealing structure as spring force when the composite sealingstructure is used as a seal. 62. The method of characterization 50further comprising: a step of vacuumizing to remove air bubbles. 63. Themethod of characterization 50 wherein: the sealing inserts each includean x-dimension that extends along an x-axis, a y-dimension that extendsalong a y-axis and a z-dimension that extends along a z-axis, whereinthe z-axis corresponds to a cable pass-through direction, and whereinthe sealing inserts are less deformable along the z-axis as compared toat least one of the x and y axes. 64. The method of characterization 50further comprising: the steps of orienting and positioning the spacermember prior to the step of impregnating the spacer member with the gelmaterial such that the composite sealing structure is more deformablealong the x-axis as compared to at least one of the y and z axes. 65.The method of characterization 50 further comprising: steps of orientingand positioning the spacer member prior to the step of impregnating thespacer member with the gel material such that the composite sealingstructure is more deformable along the x-axis as compared to both the yand z axes. 66. The method of characterization 50 wherein: the spacermember is a preform three-dimensional structure that is impregnated withthe gel material, the preform three-dimensional structure providing aself-supporting shape of the spacer member. 67. The method ofcharacterization 50 wherein: the spacer member is a braided spacerfabric. 68. The method of characterization 67 wherein: the spacer fabrichas a thickness of up to 25 mm. 69. The method of characterization 50wherein: the spacer member is a textile. 70. The method ofcharacterization 69 wherein: the textile is a woven substrate. 71. Themethod of characterization 50 wherein: the strips generated have a widthof at least 5 mm. 72. The method of characterization 50 wherein: thestep of impregnating the spacer member is by an overmold process. 73.The method of characterization 50 wherein: the step of impregnating thespacer member is by a coating process. 74. The method ofcharacterization 50 wherein: the spacer member includes an open-cellporous structure. 75. The method of characterization 50 wherein: thespacer member is a folded, layered, or stacked structure. 76. A methodfor making a seal for use in sealing a telecommunications component, themethod characterized by a step of: printing a gel material in alayer-by-layer manner to form a three dimensional cable seal formed bymultiple layers printed one on top of the other, the gel material havinga durometer less than 30 on the Shore-000 scale. 77. The method ofcharacterization 76 wherein: the gel material is one or more of siliconegel, hydro carbon gel, urethane gel, thermoplastic gel, and geloidsealing material. 78. The method of characterization 76 wherein: the gelmaterial has a durometer within 5 to 50 on the Shore-A scale. 79. Themethod of characterization 76 wherein: the component is an enclosure.80. The method of characterization 76 wherein: the component is atelecommunications cable. 81. The method of characterization 76 furthercomprising: a step of printing at least one reinforcing structure in alayer-by-layer manner along a printing axis along with the printing ofthe gel material such that the at least one reinforcing material isembedded in the gel material. 82. The method of characterization 76wherein: the step of printing the gel material includes feeding the gelmaterial to enter one end of a flow passage of a dispensing nozzlehaving a discharge orifice on another end. 83. The method ofcharacterization 81 wherein: the step of printing the at least onereinforcing structure includes feeding the at least one reinforcingstructure to enter one end of a flow passage of a dispensing nozzlehaving a discharge orifice on another end. 84. The method ofcharacterization 81 wherein: the step of printing the gel material andthe at least one reinforcing structure includes feeding both the gelmaterial and the at least one reinforcing structure together to enterone end of a single flow passage of a dispensing nozzle having a singledischarge orifice on another end. 85. The method of characterization 81wherein: the step of printing the three-dimensional gel materialincludes feeding the gel material to enter one end of a first flowpassage of a first dispensing nozzle having a first discharge orifice onanother end, and the step of printing the at least one reinforcingstructure includes feeding the at least one reinforcing structure toenter one end of a second flow passage of a second dispensing nozzlehaving a second discharge orifice on another end. 86. The method ofcharacterization 81 wherein: the step of printing the three-dimensionalgel material includes feeding the gel material to enter one end of afirst flow passage of a dispensing nozzle, and the step of printing theat least one reinforcing structure includes feeding the at least onereinforcing structure to enter one end of a second flow passage of thedispensing nozzle, the dispensing nozzle having a single dischargeorifice on another end, the gel material and the at least onereinforcing structure both exiting the single discharge orifice. 87. Themethod of characterization 81 wherein: the step of making the sealincludes: feeding the gel material to enter one of a first flow passageof a first dispensing nozzle having a first discharge orifice on anotherend; feeding the at least one filament material to enter one end of asecond flow passage of a second dispensing nozzle having a seconddischarge orifice on another end; printing alternate layers of the gelmaterial and the at least one filament material; and during thedispensing step, moving the first and second dispensing nozzles in aplane defined by first and second directions to form the seal. 88. Themethod of characterization 87 wherein: a third dispensing nozzle is usedto print a second filament different from the at least one filamentmaterial. 89. The method of characterization 76 wherein: the seal isformed by three-dimensional printing the gel material such that the gelmaterial is conformal to a finished and curved surface. 90. The methodof characterization 76 further comprising: a step of embedding at leastone reinforcing structure into the gel material of the seal. 91. Themethod of characterization 90 wherein: the step of embedding the atleast one reinforcing structure is by an overmold process. 92. Themethod of characterization 90 wherein: the step of embedding the atleast one reinforcing structure is by an extrusion process. 93. Themethod of characterization 90 wherein: the step of embedding the atleast one reinforcing structure is by a three-dimensional process. 94.The method of characterization 90 wherein: the at least one reinforcingstructure is a textile. 95. The method of characterization 90 wherein:the at least one reinforcing structure is a preform three-dimensionalstructure providing a self-supporting shape. 96. The method ofcharacterization 76 wherein: the step of printing includes printing areinforcing structure that provides the gel material with anisotropicdeformation characteristics. 97. A method of conformal printing within atelecommunications enclosure, the telecommunications enclosure defininga perimeter sealing region in a perimeter channel, and a cable sealingregion in a cable sealing cavity, the method characterized by a step of:printing a gel material directly into the perimeter channel in alayer-by-layer manner to form a three dimensional cable seal formed bymultiple layers printed one on top of the other, the gel material havinga durometer less than 30 on the Shore-000 scale. 98. The method ofcharacterization 97 further comprising a step of printing a reinforcingstructure directly into the cable sealing cavity of thetelecommunications enclosure. 99. The method of characterization 97wherein: the step of printing includes printing a reinforcing structurethat provides the gel material with anisotropic deformationcharacteristics.

The principles, techniques, and features described herein can be appliedin a variety of systems, and there is no requirement that all of theadvantageous features identified be incorporated in an assembly, systemor component to obtain some benefit according to the present disclosure.

From the forgoing detailed description, it will be evident thatmodifications and variations can be made without departing from thespirit and scope of the disclosure.

1-24. (canceled)
 25. A method of fabricating an anisotropic compositeseal for telecommunications enclosures, the method comprising the stepsof: constructing a spacer member that is adapted to define an openporous structure of the anisotropic composite seal; impregnating thespacer member with a gel material to form a composite sealing structure;and dividing the gel impregnated spacer along cut lines transverse tothe slits to form a plurality of sealing inserts each with an openporous structure, each one of the sealing inserts having a constructionwith anisotropic deformation characteristics.
 26. The method of claim25, wherein the step of dividing the gel impregnated spacer member is bynon-mechanical, cutting-energy to provide the sealing inserts inprecisely sized portions.
 27. The method of claim 26, wherein thenon-mechanical, cutting-energy providing medium is a high-pressure waterjet.
 28. The method of claim 25, further comprising a step of slittingthe spacer member to provide multiple slits therein prior to the step ofimpregnating the spacer member.
 29. The method of claim 25, furthercomprising a step of pre-compressing the spacer member prior to the stepof impregnating the spacer member.
 30. The method of claim 25, whereinthe step of pre-compressing the spacer member is performed within amold.
 31. The method of claim 30, wherein the step of impregnating thespacer member is performed while in the mold.
 32. The method of claim31, further comprising a step of bonding a substrate to the spacermember while inside the mold, the substrate being bonded to the spacermember using the gel material.
 33. The method of claim 32, wherein thesubstrate is a peelable protective layer to help facilitate handling ofthe composite sealing structure or for protecting the composite sealingstructure from contamination.
 34. The method of claim 25, furthercomprising a step of vacuumizing to remove air bubbles. 35-50.(canceled)